Ucrete® Application Manual

July 2018 Page 1

Ucrete Industrial Flooring
Application Manual CONTENTS

SECTION A INTRODUCTION

1 Introduction page 4
2 Product Overview page 4
3 General Application Guidelines page 5
3.1 Laying Rates page 6
4 Site Storage page 7
4.1 General page 7
4.2 Cold Temperatures page 7
4.3 Hot Temperatures page 7
4.4 Relative Humidity page 7
4.5 Safety Notes page 7

SECTION B PREPARATION OF SUBSTRATES

5 PREPARATION OF SUBSTRATES page 8
5.1 Substrates page 8
5.1.1 Suitable page 8
5.1.2 Unsuitable page 8
5.2 Design and Preparation of Concrete Substrates page 9
5.2.1 Floor Base/Slab page 9
5.2.2 Expansion Joints page 9
5.2.3 Damp-proofing Membranes page 9
5.2.4 Screeds page 10
5.2.5 Preparation/General Requirements page 10
5.2.6 Moisture page 11
5.2.7 Holes/Cracks page 11
5.2.8 Tolerances page 11
5.2.9 Falls page 11
5.2.10 Coves page 12
5.2.11 Areas around ovens page 12
5.2.12 Cold Rooms & Freezers page 12
5.2.13 Edge Details page 12
5.2.14 Anchor Grooves page 12
5.2.15 Other substrates page 13
5.3 Priming page 13
5.4 Planning the Laying page 14
5.5 Working in Food Factories page 15
5.6 Detail Illustrations page 16-27

SECTION C MIXING STANDARD UCRETE MATERIALS

6 MIXING page 28
6.1 Equipment page 28
6.2 Notes Regarding Packaging and Units page 29
6.2.1 Ucrete Components page 29
6.2.2 Ucrete Units page 29
6.2.3 Ucrete Part 4 Liquid Pigment Sachets page 30
6.3 Mixing Procedure page 30
6.4 Guide to Ucrete Fast Systems page 34

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Ucrete Industrial Flooring
Application Manual CONTENTS

SECTION D PRODUCTS

7.1 Primer FS page 35

7.2 Primer RG page 37
7.3 Ucrete RG page 39
7.4 Ucrete DP page 41
7.5 Ucrete HF60RT page 46
7.6 Ucrete HF100RT page 48
7.7 Ucrete IF page 50
7.8 Ucrete MF page 51
7.9 Ucrete MF40AS page 53
7.10 Ucrete MT page 56
7.11 Ucrete UD200 page 58

SECTION E SPECIAL TECHNIQUES

8 SPECIAL TECHNIQUES page 60

8.1 Earthing Anti-Static Systems page 60
8.1.1 Earth Linkages page 60
8.1.2 Copper Tape Geometry page 61
8.2 Channels & Sumps page 64
8.3 Dairy Grids page 65
8.4 Repairing Previously Laid Ucrete Flooring page 66

SECTION F HEALTH & SAFETY

9 HEALTH & SAFETY page 67

9.1 Protective Equipment page 67
9.2 Treatment of Spillages page 67
9.2.1 Part 1 and Part 4 for all Ucrete scratch coating, flooring and vertical grades page 67
9.2.2 Part 2 for all Ucrete scratch coating, flooring and vertical grades and page 67
Topcoat PU CLEAR
9.2.3 Part 3 for all UCRETE priming, flooring and vertical grades, Part 5 and page 67
all FILLER grades
9.3 Disposal page 68
9.3.1 Part 1 and Part 4 for all UCRETE priming, flooring and vertical grades page 68
9.3.2 Part 2 for all UCRETE priming, flooring and vertical grades and page 68
TOPCOAT PU CLEAR
9.3.3 Part 3 for all UCRETE priming, flooring and vertical grades, Part 5 grades page 68
and all FILLER
9.4 Solvents page 68

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Section A: Introduction

1. INTRODUCTION
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.

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.

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

2. PRODUCT OVERVIEW
UCRETE Unit weight kg Coverage kg/m2 Min site/slab
application temp
°C
PRIMER FS 12.69 0.6 – 2.0 5
PRIMER RG 1.43 0.15 – 0.2 5
BASECOAT BC4 18.88 6 – 8 @ 3mm 12
BASECOAT BC6 23.18 10 – 12 @ 5mm 8
BASECOAT BC9 26.88 16 – 18 @ 8mm 8
TOPCOAT 3.72 0.4 – 1.2 8
TOPCOAT GLOSS 3.78 0.4 – 1.2 8
HF60RT 28.38 13 - 15 at 6mm 12
HF100RT 28.38 20 - 21 at 9mm 8
IF 35.53 28 – 30 at 9mm 5
MF 20.28 8 – 10 at 4mm 12
12 – 14 at 6mm
MF40AS 17.72 8 – 10 at 4mm 18
MT 25.73 10 – 12 at 4 – 6mm 8
RG 11.80 8 - 10 at 4mm 5
12 - 14 at 6mm
18 - 20 at 9mm
UD200 30.53 15 - 16 at 6mm 5
21 - 22 at 9mm

Notes:

Wastage The figures quoted allow for some wastage but do not include 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 A: Introduction

3. GENERAL APPLICATION GUIDELINES

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.

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.

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.

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 applied working into Mix 3 but Mix 2 can no
longer be touched
• …and so on, until the end of the bay is reached.

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 seams in main
traffic aisles where they will stand out. These should be discussed with the client before starting to lay
the floor.

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.

Use battens wrapped in brown parcel tape, or similar, to provide a straight edge to the bay.
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.

Mask off all adjacent surfaces.

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

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.

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Section A: Introduction
Masking tapes should be removed after ~1 hour.

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.

3.1. LAYING RATES

Site conditions influence laying rates.

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 HF100RT 150-200m²

• UCRETE UD200/UD200SR 100-150m²
• UCRETE DP 150-200m²
• UCRETE MF 150-200m²
• UCRETE MF40AS 150-200m²

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 HF60RT 300-600 m2

• UCRETE HF100RT 200-400 m²
• UCRETE DP 200-800 m² depending upon thickness
• UCRETE MF 300-600 m²
• UCRETE MFAS/MF40AS 300-500 m²

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Section A: Introduction

4. SITE STORAGE
4.1 General

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 hard and lumpy and unsuitable for use.

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.

Provided these storage conditions are maintained, most components have a shelf life of 9 months. All
UCRETE and ancillary products are clearly marked with a use-by date. Do not exceed it without
reference to BASF Construction Chemicals.

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

When site temperatures fall below 15°C the following should be considered:
1. All grades of UCRETE will become more difficult to apply, consequently laying rates are reduced.
2. In each section minimum application temperatures are specified these should be maintained to
ensure the expected finish is achieved.
3. 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

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.

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

4.4 Relative Humidity

If the relative humidity drops below 50%, this can increase the time to become tack free for all grades of
UCRETE, including primers. If the humidity is below 30%, this can extend for several days. If primers or
basecoats are overlaid before they are dry/tack free this can lead to blistering.

4.5 Safety Notes

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
• Exterior grade plywood (25mm marine ply)

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.

5.1.2 Unsuitable

Known to be unsuitable are:

• Unmodified sand/cement screeds

• Asphalt/bitumen
• Bricks or block paviours
• Magnesite
• Galvanised steel
• Stainless steel
• Copper
• Aluminium
• Wood (except exterior grade plywood)
• Aerated concrete blocks
• Tiled floors
• Natural Stone

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.

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Section B: Preparation of substrates

5.2 Design and Preparation of Concrete Substrates

5.2.1 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.

5.2.2 Expansion Joints (see Figures 5 and 6)

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.

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.

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

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.

5.2.3 Damp-proofing Membranes

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.

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

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

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Section B: Preparation of substrates
5.2.4 Screeds

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:

a. Fine concrete must be minimum 75 mm thick and have a direct tensile strength of 1.5MPa with
appropriate reinforcement.
b. 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.
c. MasterEmaco T 920CI or MasterEmaco T 545

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

All bonded screeds greater than 70 mm thick should be reinforced with appropriate steel mesh
reinforcement 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 screeds.

Steel mesh reinforcement must be a minimum of 25 mm below the surface, especially in extreme
thermal shock environments.

5.2.5 Preparation/General Requirements

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.

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

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.

All substrates will require preparation. Cementitious substrates must be mechanically prepared so that
the large aggregate of the concrete/ screed is exposed. 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
• Flame spalling may be satisfactory in some situations

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Section B: Preparation of substrates

Acid etching is not reliable and should not be used.

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

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

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.

5.2.6 Moisture

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.

• UCRETE is tolerant of residual moisture in the substrate concrete/screed, however, the surface
must be visibly dry.
• The substrate temperature should be at least 3°C above the dew point during application.
• Do not apply when atmospheric condensation is occurring or likely to occur before full cure is
obtained.
• Care should be taken when using propane heaters in cold conditions. The water produced by
these heaters can often cause condensation.

5.2.7 Holes/Cracks

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 5400CI or T 920. Ensure sufficient material has been
allowed for. With UCRETE MF any irregularities should be filled with the scratchcoat primer, to ensure an
even final finish.

All repairs to the substrate must be completed in good time prior to the application of the UCRETE floor

5.2.8 Tolerances

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.

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

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.

5.2.9 Falls

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

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Section B: Preparation of substrates
minimum and maximum thickness.

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 HF60RT & HF100RT can be laid to falls as steep as 1:50
• UCRETE IF can be laid to falls as steep as 1:25
• UCRETE MF & MF40AS can be laid to falls not exceeding 1:100
• UCRETE MT can be laid to falls as steep as 1:20
• UCRETE UD200 can be laid to falls as steep as 1:20

5.2.10 Coves (See Section 5.5 Detailed Illustrations)

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.

5.2.11 Areas around Ovens

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.

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.

5.2.12 Cold Rooms and Freezers

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.

5.2.13 Edge Details (See Section 5.5 Detailed Illustrations.)

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.

5.2.14 Anchor Grooves

Wherever a free edge of UCRETE flooring will occur, for example, around the perimeter of a bay, along
channels 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.

This is achieved by forming or 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.

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Section B: Preparation of substrates
Suggestions for various situations are shown in the Section 5.5 Detailed Illustrations.
On a new floor, grooves may be formed by inserting polyethylene-film-coated timber strips into the
concrete at the time of laying. Grooving has the additional important advantage of reducing the
possibility of liquid seeping under the UCRETE flooring and affecting the bond to the substrate.

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.
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.

5.2.15 Other Substrates

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

Additional special points are:

• 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.

• Exterior grade plywood - should be at least 25mm thick. The boards must be securely screwed at
30cm centres with the joints fully supported and reinforced with polyester glass fibre mesh or
expanded metal scrim. The surface should be sanded lightly and cleaned by vacuum. Provided the
board is dry, UCRETE flooring can then be applied in the normal way.

• 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.

5.3 Priming

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 primed prior to the application of UCRETE
flooring. Priming 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.

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

Note: A poor quality or contaminated substrate cannot be made satisfactory by priming.

Some concretes and screeds contain bleed run pores which are hard to seal and may require double
priming. In these cases, it is normal to prime with a thin coat primer first and then with a UCRETE
scratch coat primer. Bleed run pores are more common in concretes that have been laid with a very
fluid consistence (high slump) and which have not been vibrated.

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Section B: Preparation of substrates

Normal priming requirements are as follows however it will depend upon the porosity of the substrate
concrete and the profile left after preparation.

 UCRETE DP Priming not normally required

 UCRETE HF100RT Thin coat priming required*
 UCRETE IF Priming not normally required. However, priming must be used
if appearance/hygiene is important
 UCRETE MF & MF40AS Scratch coat priming required
 UCRETE MT Thin coat priming required*
 UCRETE UD200 Thin coat priming*. Priming must be used if appearance/hygiene
is important
 UCRETE RG PRIMER RG
* Can always be replaced with a scratch coat primer if desired

Thin Coat Primer

PRIMER FS ~ 0.6 kg/m2 - applied by squeegee

Scratch Coat Primer

PRIMER FS ~ 1 - 1.5 kg/m2 - applied by squeegee
UCRETE MF, MF40AS, BC4, BC6 ~ 2 - 4 kg/m2 or more - applied by trowel

Typical overcoat time for primers

@10°C @20°C Maximum

PRIMER FS 4 hours 3 hours 30 hours
A UCRETE scratch coat 24 hours 16 hours 48 hours

5.4 Planning the Laying

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

• 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.

• 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 for each product
is in Section 7.

• 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.

• 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.

• As a visual aid to achieving the correct thickness and a level floor, the area to be covered by

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Section B: Preparation of substrates
individual mixes could be marked by chalk lines on the substrate, for example.

5.5 Working in Food factories

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

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 customer cannot remove food
then enclosures and extraction systems will be required. The applicator and the customer must agree
on the best solution.

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

• 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.
• 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.
• The protection of adjacent plant and equipment from resin splash and dust.

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 resin
lining.

© BASF Australia Ltd, Page 15

Section B: Preparation of substrates

5.6 DETAILED ILLUSTRATIONS

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

Termination, At free edge

Termination, At Stop Bead

© BASF Australia Ltd, Page 16

Section B: Preparation of substrates
5.6 DETAILED ILLUSTRATIONS, continued

Termination, At Wall

Termination, To Old UCRETE

© BASF Australia Ltd, Page 17

Section B: Preparation of substrates
5.6 DETAILED ILLUSTRATIONS, continued

Cove, Flush

Cove, Sit On

© BASF Australia Ltd, Page 18

Section B: Preparation of substrates
5.6 DETAILED ILLUSTRATIONS, continued

Cove, To Curb

Cove, To Insulated Panel

© BASF Australia Ltd, Page 19

Section B: Preparation of substrates
5.6 DETAILED ILLUSTRATIONS, continued

Cove, To Cladding

Joint, Movement

© BASF Australia Ltd, Page 20

Section B: Preparation of substrates
5.6 DETAILED ILLUSTRATIONS, continued

Joint, Induced

Channel, Stainless Steel, A

© BASF Australia Ltd, Page 21

Section B: Preparation of substrates
5.6 DETAILED ILLUSTRATIONS, continued

Channel, Stainless Steel, B

Channel, Fully Lined

© BASF Australia Ltd, Page 22

Section B: Preparation of substrates
5.6 DETAILED ILLUSTRATIONS, continued

Channel, >400mm Rendered

Channel, <400mm Rendered

© BASF Australia Ltd, Page 23

Section B: Preparation of substrates
5.6 DETAILED ILLUSTRATIONS, continued

Plinth, Less Than 300mm, A

Plinth, Less Than 300mm, B

© BASF Australia Ltd, Page 24

Section B: Preparation of substrates
5.6 DETAILED ILLUSTRATIONS, continued

Plinth, More Than 300mm

Low Bund Wall

© BASF Australia Ltd, Page 25

Section B: Preparation of substrates
5.6 DETAILED ILLUSTRATIONS, continued

Bund Lining

Blind Sump

© BASF Australia Ltd, Page 26

Section B: Preparation of substrates
5.6 DETAILED ILLUSTRATIONS, continued

Mild Steel Mezzanine

© BASF Australia Ltd, Page 27

Section C: Mixing Standard Ucrete Materials

6 MIXING
UCRETE flooring products are 3 or 4 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.

7.1 Equipment

The small units of PRIMER FS, PRIMER RG, PRIMER SC, UCRETE TOPCOAT and TOPCOAT GLOSS
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 except MF40AS
Mixal MR40 All except MF40AS
Imer mixer All except MF40AS
Pennine Casco G5/G8:
Triple blade BC4, BC6, MF
Single blade All except BC4, BC6, MF, MF40AS & all primers
Collomatic XM2 650 or similar All grades

Slow speed drills, < 350 RPM BC4, BC6, Topcoats, MF, MF40AS & all primers
Slow speed planetary mixer like a Soroto UD 200, B9, IF
Twin headed mixing drills, < 350 RPM BC4, BC6, BC9, MF, HF60RT, HF100RT
Twin headed mixing drills, < 150 RPM All grades

Other mixers should be checked for efficiency before use. Do not mix by hand.
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.

Ensure Mixing paddles are properly adjusted and close to the bottom of the mixer. Some mixers have a dead
spot and mixing regimes must be adjusted to allow for these to be raked out during every mix.

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. The diameter of the mixing head should be more than half the diameter of the mixing bucket

Mortar grades, UCRETE IF, MT, and UD200 should not be mixed with a normal drill and paddle, especially
when using fast systems.

UCRETE RG is best mixed using a small mortar mixer such as the Mixall MR40 or the Imer mixer. It can also
be mixed using a Twin headed mixing drill at <150 RPM.
UCRETE RG can NOT be mixed with a normal drill and paddle.

© BASF Australia Ltd, Page 28

Section C: Mixing Standard Ucrete Materials
7.2 Notes Regarding Packaging and Units

7.2.1 Ucrete components

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.

• UCRETE Part 1 with a WHITE cap is for NON pigmented products

• UCRETE Part 1 with a YELLOW cap is for PIGMENTED products

• UCRETE Part 1 with a Green label is for normal NON pigmented products (which have WHITE
caps) UCRETE Part 1 with a Yellow label is for normal PIGMENTED products (which have
YELLOW caps) UCRETE Part 1 with a Red label is for FAST products (which have WHITE caps
(primers) or YELLOW caps (products))

UCRETE Part 2 is a brown liquid in a white plastic bottle, 4 to a box

• UCRETE Part 2 bottles have a BLUE cap and a WHITE label

UCRETE Part 3 is an off white powder

• UCRETE Part 3 is in printed white paper valve sacks or clear polythene sacks for small quantities.
Note that UCRETE FL has two Part 3’s.

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

• UCRETE Part 4 Sachets:- for pigmented grades. Use whenever the Part 1 has a YELLOW cap

UCRETE Part 5
A few products have a 5th component

• BASECOAT BC9 has an optional thickening agent 5th component

• UCRETE IF has a metallic 5th component

7.2.2 Ucrete UNITS

A UCRETE unit consists of:

• UCRETE Part 1
• UCRETE Part 2
• UCRETE Part 3
• UCRETE Part 4 – for pigmented products only

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

© BASF Australia Ltd, Page 29

Section C: Mixing Standard Ucrete Materials

7.2.3 Ucrete Part 4 LIQUID PIGMENT sachets

The pigment in the sachet is dispersed in part of the resin. If the UCRETE Part 1 has a yellow top, 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. If the UCRETE Part 1 has a white cap, a Part 4 pigment pack must
not be used as otherwise the resin to hardener ratio will be wrong and the material will lose its chemical
and physical properties.

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.

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.

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.

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.

The recommended method of emptying the sachet once the top has been removed is detailed below:

• Hold the sachet loosely in the palm between the thumb and fingers vertically.
• Tip the sachet directly into the Part 1 and 2 avoiding contamination of the sides of the mixing vessel.
• 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.
• It is not normally necessary to repeat the above step to remove more material.

Note that it is possible to do a double mix with each unit having a different colour pigment pack. For
example, mixing a blue unit and a grey unit together would give a “Pigeon Blue” mixing a yellow unit and
a cream unit gives a “Light Yellow” red and green give brown.

7.3 Mixing Procedure

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

a) 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.

b) 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
turnaround 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).

© BASF Australia Ltd, Page 30

Section C: Mixing Standard Ucrete Materials

c) 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. When using Fast Part 1 (with a red label) do not exceed
20 seconds mixing regardless of mixer type.

When using Part 1 in a bottle with a YELLOW label and a YELLOW cap, a UCRETE Part 4 sachet
must be used.
Therefore the liquid components are: Part 1, Part 2 and UCRETE Part 4 sachet

When using Part 1 in a bottle with a RED label and a YELLOW cap, UCRETE Part 4 sachet must
be used.
Therefore the liquid components are: Part 1, Part 2 and UCRETE Part 4 sachet

When using Part 1 in a bottle with a RED label and a WHITE cap, UCRETE Part 4 sachet must not
be used.
Therefore the liquid components are: Part 1, Part 2 only

When using Part 1 in a bottle with a GREEN label and a WHITE cap a UCRETE Part 4 sachet must
not be used.

Therefore the liquid components are: Part 1 and Part 2 only

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.

d) 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.

e) 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.

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.

The required mixing time may be judged with experience and will depend on the individual grade,
the efficacy of the mixer and the number of units mixed. The table below should be used as a guide
(note this excludes primers and anti-static system, please see separate product information).

© BASF Australia Ltd, Page 31

 Section C: Mixing Standard Ucrete Materials

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

When using Fast systems, do not extend the mix time at lower temperatures but mix for 2 – 3 minutes
depending upon temperature and mixer efficiency.

Once the mix time is determined keep constant throughout the application.
Large variations in mix time can produce variations in colour shade and surface texture.
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.

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

g) 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.

Mixes larger than 3 units should not be undertaken.

Notes:

1. 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.

To ensure the time between mixes is kept to a minimum the mixer should either:

a) have two mixing vessels/containers which are rotated;

OR

b) have the facility to tip the mix contents into a separate container for transportation to the
application area, i.e. wheelbarrow.

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

• poor aggregate dispersion

• poor flow
• excessive trowel marking
• pimples or blisters in the cured floor
• surface unevenness

3. Spillages of components onto the substrate to be coated must be avoided as this may cause
blisters when the area is coated later.

© BASF Australia Ltd, Page 32

Section C: Mixing Standard Ucrete Materials
4. 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.

5. 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. 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.

© BASF Australia Ltd, Page 33

Section C: Mixing Standard Ucrete Materials
7.4 Guide to UCRETE Fast Systems

a) 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.
• Using the Normal Part 1 gives the maximum open time at all temperatures and normal curing
times
• Using the Fast Part 1 gives the fastest curing times especially for use at low temperature
• Mixing two units with one Fast Part 1 and one Normal Part 1 gives intermediate curing rates

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

TABLE OF CURE TIMES

PRIMER FS Fast F+N Normal

= Fast PART 1 a double mix with one = Normal

Normal and one Fast PART 1
PART 1

25 3 Do Not Use Do Not Use 12

Site Temperature °C

20 3 Do Not Use 4 16

15 4 4 6 20

10 4 5 8 24

5 7 7 12 30
Overcoat
Time, Time To Traffic, Hours
Hours

Note: N = a mix with Normal Part 1

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

d) Do NOT use the Fast Part 1s with TC, TC GLOSS, HR60RT, HF100RT, MF, MF40AS or RG

e) 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.

f) 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.

g) 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 34

Section D: Products
7.1 PRIMER FS

Three component heavy duty polyurethane slurry coat primer

PRIMER FS is intended for use under all grades of UCRETE and is especially suited for applications
where a short overcoat time is required.

7.1.1 Limitations

PRIMER FS should not be applied onto:

• Wet substrates - Concrete and other cementitious substrates must be visibly dry.
• Weak substrates - the average pull-off strength shall be 1.5N/mm². Application to substrates of lower
strength may affect the long-term performance of the applied flooring. This is particularly relevant in
areas subject to heavy use, be it thermal or mechanical.

7.1.2 Packaging

Part 1 2.83 kg
Part 2 2.86 kg
Part 3 7.00 kg
12.69 kg net per unit

7.1.3 Coverage

Coverage is greatly influenced by substrate texture and porosity.

Typical coverage rates are:

0.6 - 2kg/m² (maximum 3.0kg/m²) 6 - 20m²/unit

Typically - 0.6kg/m² for thin coat applications where otherwise PRIMER SC might be used
Typically - 1.0-1.5kg/m² for scratch coat applications

7.1.4 Mixing

Temperature requirements: site temperatures 5 - 30°C, material temperatures 10 - 20°C.

Particular attention should be paid to Section C above.

Mix single units in a suitable sized mixing vessel with an electric drill and helical paddle.

Mix the liquid components for 20 seconds until homogenous add the powder components and mix for a
further 2 minutes.

Note: If 2kg or more of mixed material is left in the mixing container for more than 10 minutes it will react
strongly, giving off considerable heat. This should be avoided and the container should be placed
to one side until reaction is complete, however no noxious fumes are given off.

© BASF Australia Ltd, Page 35

Section D: Products
7.1.5 Application

The air and substrate temperature during application should be above 5°C.

8 x 8mm anchor grooves under 4mm floors should be filled with PRIMER FS. Do not fill larger anchor
grooves with PRIMER FS but ensure these are brushed out.

Tip the mixed primer across the floor immediately after mixing as otherwise it will exotherm very quickly.
PRIMER FS is applied as a slurry primer using a soft foam squeegee pulling over the surface in both
directions to fill the pores and voids in the surface. If using under UCRETE MF, do not pull out too thinly,
but take care to leave a continuous coating over the surface to ensure the substrate is completely sealed.

Do not use for filling and levelling

If left overnight in cold conditions, or where the day/night temperature change is great, particular care
should be taken that condensation does not occur on the PRIMER FS. This can be difficult to see and
can lead to blistering of the body coat if it is not removed.

7.1.6 Curing

Prior to application of a subsequent coat, check that the surface is hard and tack-free. The recoating time
is dependent upon humidity and temperature, but typically PRIMER FS can be overlaid:-

After 7 hours at 5°C

After 4 hours at 10 - 15°C
After 3 hours at 20°C
After 2 hours at 30°C

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.

If the time between coats exceeds 30 hours, or if condensation or water impacts the surface, fully abrade
the surface prior to overlaying.

© BASF Australia Ltd, Page 36

Section D: Products
7.2 PRIMER RG

Three component heavy duty polyurethane primer for use with UCRETE RG

It is used on all substrates such as concrete and other cementitious substrates, exterior grade plywood,
mild steel and plastic-coated insulation panels.

7.2.1 Limitations

PRIMER RG should not be applied onto:

• Wet substrates - The surface of concrete and other cementitious substrates must be visibly dry.
• Weak substrates - the average pull-off strength shall be 1.5N/mm². Application to substrates of lower
strength may affect the long-term performance of the applied finish. This is particularly relevant in
areas subject to heavy use, be it thermal or mechanical.

7.2.2 Packaging

Part 1 0.56 kg
Part 2 0.57 kg
Part 3 0.30 kg
1.43 kg net per unit

7.2.3 Coverage

Coverage is greatly influenced by substrate texture and porosity.

Typical coverage rates are:-

0.15 - 0.2kg/m² or 7 - 9m² per unit

Please note that especially when coving there is likely to be considerable wastage of PRIMER RG as all
primed surfaces must be overlaid with UCRETE RG within approximately 1 hour depending upon
substrate porosity and temperature

7.2.4 Mixing

Pour the contents of the Part 1 can, Part 2 can into a 2.5 litre polyethylene mixing pail and mix using a
Helical "Epi" type mixer in an electric drill operated at 350 rpm for 30 seconds.

Add the Part 3 bag and continue mixing for a further 1-2 minutes or until the mix becomes homogeneous.

The working life is approximately 10 minutes.

7.2.5 Application

Temperature requirements: site temperatures 5 - 30°C, material temperatures 16 - 22°C. The air and
substrate temperature during application should be above 5°C.

PRIMER RG should be applied by roller and/or brush. If applying by brush, it is normally necessary to
remove excess primer with a short pile roller

Apply sufficient to wet out the substrate, ensuring there is no excess material on the surface otherwise
the UCRETE RG will slide off the wall

© BASF Australia Ltd, Page 37

Section D: Products

Apply the material around the edges of areas and into anchor grooves (chases) by brush to ensure even
coverage. Do not fill the anchor grooves with PRIMER RG.

Only apply as much PRIMER RG as can be covered within the open time.

7.2.6 Curing

UCRETE RG is applied immediately after the application of the PRIMER RG while the PRIMER RG is still
wet.

The open time of PRIMER RG is ~ 60 minutes at 20°C. Do not apply UCRETE RG after this time.

If the open time of the primer is exceeded, leave to cure overnight. Re-prime and apply UCRETE RG as
normal.

If the time between coats exceeds 48 hours, or if condensation or water impacts the surface, fully abrade
the surface. Re-prime and apply UCRETE RG as normal.

© BASF Australia Ltd, Page 38

Section D: Products
7.3 UCRETE RG

Heavy duty polyurethane render grade and coving mortar

7.3.1 Packaging

Part 1 0.71 kg
Part 2 1.09 kg
Part 3 9.50 kg
Part 4 0.50 kg
11.80 kg net per unit

7.3.2 Coverage

3 mm 7-8 kg/m²*
4 mm 8-10 kg/m²*
6 mm 12-13 kg/m²*
9 mm 18-20 kg/m²*

* These figures do not take into account the cove radius.

7.3.3 Planning

On large surfaces plan the application carefully to ensure a wet edge is maintained at all times.

7.3.4 Priming

Prime surfaces with PRIMER RG and apply UCRETE RG to the primer wet in wet, within the open time
of the primer.

7.3.5 Mixing

Temperature requirements: site temperatures 5 - 30°C, material temperatures 15 - 22°C

Mix in a forced action mixer. Particular attention should be paid to Section C and the table of mixing times.

Ideal on site are Penine, Danes Mixal or Imer mixers. It is not possible to mix UCRETE RG with a normal
drill and paddle. Too rapid mixing will entrain large amounts of air and can break the thixotropy of the
mortar. However, good results can be achieved with a twin headed mixing drill with a speed of
<150rpm.

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

7.3.6 Application

Ensure that the PRIMER RG has been correctly applied to the surface of the substrate.

Empty the material out of the mixing vessel as soon as possible, along the cove or onto a board, to help
maximise the working time.

Apply UCRETE RG by trowel, a normal application being in layers of 3-6 or 9mm depending upon the
specification. Special coving trowels are available and can be used. Stainless steel or plastic trowels will
minimise the risk of trowel burn and are recommended, especially with lighter colours.

© BASF Australia Ltd, Page 39

Section D: Products

Close the surface with a short pile roller, taking care not to overwork.

In most circumstances, 9mm of UCRETE RG can be applied to the vertical in a single application.

When applying large areas which cannot be installed in one operation, for example a bund wall, use a
Lap Joint as shown in the detail below to join the sections of UCRETE RG.

Lap Joint detail for a day work joint in UCRETE RG

© BASF Australia Ltd, Page 40

Section D: Products

7.4 UCRETE DP

Heavy duty polyurethane defined profile flooring

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.

UCRETE DP10 is produced by broadcasting Filler F10

UCRETE DP20 is produced by broadcasting Filler F20
UCRETE DP30 is produced by broadcasting Filler F25

For a 4mm floor use UCRETE Basecoat BC4

For a 6mm floor use UCRETE Basecoat BC6
For a 9mm floor use UCRETE Basecoat BC9

7.4.1 Packaging

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

UCRETE Basecoat BC4: 18.88kg unit 2.52 kg 2.86 kg 13.00 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 4.0kg*

* BASECOAT BC9 Part 5 is only added when applied at high temperatures and steep falls
Filler F10 25kg per bag
Filler F20 25kg per bag
Filler F25 25kg per bag

Part 1 Part 2 Part 3 Part 4

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

UCRETE Topcoat Gloss 3.78 kg unit 0.83KG 1.09KG 1.36KG 0.5KG

NOTE: Apart from the Part 4 liquid pigment, there are no components of UCRETE TOPCOAT Gloss and
the standard TOPCOAT that are common to both products. The different components must not be mixed.

NOTE: Non Pigmented Basecoats

By replacing UCRETE Part 1 for MF/MFAS/PIG BC 2,52KG with the UCRETE Part 1 for BC/BCAS/FL
2.83KG and omitting the Part 4 pigment sachet a non-pigmented Basecoat can be produced.

Non-Pigmented Basecoats Part 1 Part 2 Part 3 Part 5

UCRETE Basecoat BC4: 18.69 kg unit 2.83kg 2.86kg 13.00kg None
UCRETE Basecoat BC6: 22.99 kg unit 2.83kg 2.86kg 17.30kg None
UCRETE Basecoat BC9: 26.69/30.69* kg unit 2.83kg 2.86kg 21.00kg 4kg

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

© BASF Australia Ltd, Page 41

Section D: Products
7.4.2 Coverage

UCRETE BASECOAT BC4 6 - 8kg/m²

UCRETE BASECOAT BC6 10 -12kg/m²
UCRETE BASECOAT BC9 16 -18kg/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 R12 floor 1.0-1.2kg/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

7.4.3 Planning

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 BASECOAT BC4 7.5m for a single mix 15m for a double mix 23m for a treble mix
For BASECOAT BC6 5.5m for a single mix 11m for a double mix 17m for a treble mix
For BASECOAT BC9 4m for a single mix 8m for a double mix 12m for a treble mix

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

7.4.4 Priming

The use of a primer 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.

On rough substrates, and on substrates with large bleed run pores, it is recommended that a scratchcoat
primer (using PRIMER FS or BASECOAT BC4) is used to produce a smooth and sealed substrate for the
application of the BASECOAT so ensuring the best aesthetic results.

Ensure the primer 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.

7.4.5 Mixing

Temperature requirements: site temperatures 8 or 12 - 30°C, material temperatures 18 - 22°C

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.

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 for BASECOAT BC4, 8°C for BASECOAT BC6 & BC9.

When discharged from the mixer the BASECOAT should be at least 18°C.

Mix the BASECOAT as per Section C.

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Section D: Products
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.

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

7.4.6 Application

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

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

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.

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

To ensure an even finish all trowelling and spiked rollering should be completed before the mix is more
than 10 minutes old.

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:

If the BASECOAT does not flow sufficiently and pin rake marks, etc. remain in the surface, even after
spike rollering, try the following remedies.

• Prime or scratchcoat the substrate

• Raise material temperature
• Increase mix time
• Increase thickness
• Remove Part 4 from BASECOAT B9 if used
• Raise substrate and or site temperature

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

7.4.7 Broadcast

The BASECOAT must be flat and smooth prior to broadcasting. Imperfections in the surface of the
BASECOAT will be seen in the finished floor.

The time at which the BASECOAT is scattered is critical:

• Too early and the surface will become uneven.

• Too late and the aggregate will not penetrate sufficiently.
• To ensure long term performance it is essential that the scatter is applied early enough to allow
absorption into the surface.

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Section D: Products

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.

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.

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
application rate of 4-5kg/m² is much higher than that usually used for scatter systems. It has been found
that this level of scatter is required to produce a consistent, durable and uniform finish.

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.

The use of the Fast Part 1 in a pigmented basecoat allows the excess aggregate to be removed and the
floor sanded ready to receive the TOPCOAT after 6 hours at 15°C

Lightly abrade the floor using a rotary sanding machine (STR 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.

7.4.8 Topcoat

Planning the application

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 R12 floor 7 m for a single mix 13.5 m for a double mix
For UCRETE DP20 R13 floor 9 m for a single mix 18 m for a double mix
For UCRETE DP30 R13 floor 7 m for a single mix 13.5 m for a double mix

On larger floors plan how the area is to be divided to produce the most practical and aesthetically
acceptable floor.
UCRETE TOPCOAT is a four-component topcoat.

Temperature requirements: site temperatures 8 - 30°C, material temperatures 18 - 22°C

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.

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 8°C.

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Section D: Products
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.

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 temperature is within 3°C of the dew
point.

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.

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.

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.

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

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.

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.

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.

Use a brush and small hand roller to coat the coving together with the floor, this produces a seamless
transition and improves aesthetics.

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

© BASF Australia Ltd, Page 45

Section D: Products

7.5 UCRETE HF60RT

Heavy duty polyurethane flow applied floor finish

7.5.1 Packaging

Part 1 2.52 kg
Part 2 2.86 kg
Part 3 22.50 kg
Part 4 0.50 kg
28.38 kg net per unit

7.5.2 Coverage

Typically - 6mm 13-15 kg/m²

7.5.3 Planning

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:

5m for a single mix 10m for a double mix 15m for a treble mix

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

7.5.4 Priming

Ensure that PRIMER FS or UCRETE MF scratch coat has been correctly applied and cured. It is important
to use a primer with this material as its fluid nature makes it susceptible to air rising from the concrete.

7.5.5 Mixing

Temperature requirements: site temperatures 12 - 30°C, material temperatures 15 - 20°C.

Mix the material as per section C. UCRETE HF60RT is best mixed in a mortar mixer. Multiple mixes from
a Cretangle or Collomatic mixer enable the advantages of speed of application to be realised. Ensure
sufficient mixing to wet out and disperse the aggregates properly.

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

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

7.5.6 Application

Spread the mix evenly over the substrate using a pin rake, this should be set to 7 – 8 mm as some
reduction in thickness will occur when the surface is finished. Use a steel trowel for edgework.

Use a spiked roller, in long gentle sweeps over the surface, to produce a smooth even finish. Over use of
the spiked roller will reduce the slip resistance of the floor, especially at higher temperatures.

© BASF Australia Ltd, Page 46

Section D: Products

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

At lower temperatures it may be necessary to close the surface over the pin marks with a steel trowel.
Avoid over-trowelling (as this will lead to a smooth floor) and use the spiked roller after trowelling to even
up the surface.

Care should be taken that the correct degree of slip resistance versus ease of cleaning is produced in line
with the end users requirements.

© BASF Australia Ltd, Page 47

Section D: Products
7.6 UCRETE HF100RT

Heavy duty polyurethane flow applied floor finish

7.6.1 Packaging

Part 1 2.52 kg
Part 2 2.86 kg
Part 3 22.50 kg
Part 4 0.50 kg
28.38 kg net per unit

7.6.2 Coverage

Typically - 9mm 20-21 kg/m²

7.6.3 Planning

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:

3.5m for a single mix 7m for a double mix 10.5m for a treble mix

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

7.6.4 Priming

Ensure that PRIMER FS or UCRETE MF scratch coat has been correctly applied and cured. It is important
to use a primer with this material as its fluid nature makes it susceptible to air rising from the concrete.

7.6.5 Mixing

Temperature requirements: site temperatures 12 - 30°C, material temperatures 15 - 20°C.

Mix the material as per section C. UCRETE HF60RT is best mixed in a mortar mixer. Multiple mixes from
a Cretangle or Collomatic mixer enable the advantages of speed of application to be realised. Ensure
sufficient mixing to wet out and disperse the aggregates properly.

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

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

7.6.6 Application

Spread the mix evenly over the substrate using a pin rake, this should be set to 10-11mm as some
reduction in thickness will occur when the surface is finished. Using a steel trowel for edgework.

Use a spiked roller, in long gentle sweeps over the surface, to produce a smooth even finish. Over use of
the spiked roller will reduce the slip resistance of the floor, especially at higher temperatures.

© BASF Australia Ltd, Page 48

Section D: Products

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

At lower temperatures it may be necessary to close the surface over the pin marks with a steel trowel.
Avoid over-trowelling (as this will lead to a smooth floor) and use the spiked roller after trowelling to even
up the surface.

Care should be taken that the correct degree of slip resistance versus ease of cleaning is produced in line
with the end users requirements.

© BASF Australia Ltd, Page 49

Section D: Products
7.7 UCRETE IF

Iron Filled heavy duty polyurethane trowel applied floor finish

7.7.1 Packaging

Part 1 2.37kg
Part 2 2.86kg
Part 3 17.30kg
Part 4 0.50kg
Part 5 12.50kg
35.53 kg net per unit

7.7.2 Coverage

Typically - 9mm 28 - 30 kg/m²

7.7.3 Planning

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:

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

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

7.7.4 Priming

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

A primer is not normally required. However, on very porous substrates and where hygiene, ease of
cleaning and appearance are important the use of a primer is required.

7.7.5 Mixing

Temperature requirements: site temperatures 5 - 30°C, material temperatures 15 - 20°C Mix in a forced
action mixer. It is not possible to mix effectively with a drill and paddle.
Mix the liquid components 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.
If using Fast Part 1 ensure sufficient manpower is available to apply properly within the potlife.

Temperatures below 15°C will make application more difficult and careful consideration should be given
to storage of materials in cold conditions.
Maintain consistent mix times throughout or the colour of the floor will be affected.

7.7.6 Application

Spread the mix evenly over the substrate and close using a steel trowel. Avoid over-trowelling as this
results in gloss variations and impaired slip resistance.
Where aesthetics are important lightly roll with a short pile roller. This will reduce slip resistance.

© BASF Australia Ltd, Page 50

Section D: Products
7.8 UCRETE MF

Heavy duty polyurethane flow applied floor finish

7.8.1 Packaging

Part 1 2.52kg
Part 2 2.86kg
Part 3 14.40kg
Part 4 0.5kg
20.28kg net per unit

7.8.2 Coverage

4mm 8 - 10 kg/m²
6mm 12 - 14 kg/m²

7.8.3 Planning

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

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

7.8.4 Priming

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

The use of PRIMER FS or UCRETE MF scratchcoat primer, 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.

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

7.8.5 Mixing

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

Temperature is critical to the correct application of the UCRETE MF. 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 12°C.

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

Mix the material as per section C.

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Section D: Products

7.8.6 Application

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

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

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.

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

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.

Notes:

• 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.

• 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.

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

© BASF Australia Ltd, Page 52

Section D: Products
7.9 UCRETE MF40AS

Heavy duty polyurethane flow applied anti-static floor finish

7.9.1 Packaging

Part 1 2.93 kg
Part 2 3.29 kg
Part 3 11.00 kg
Part 4 0.50 kg
17.72 kg net per unit

7.9.2 Coverage

4mm 8-10 kg/m²

6mm 12-14 kg/m²

7.9.3 Planning

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

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

7.9.4 Priming

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

The use of PRIMER FS or UCRETE MF scratchcoat primer, 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.

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

Earthing: See section 8.1 for details of earth connections.

Install copper tapes and linkages, abrading the primer with emery paper and removing dust by vacuum
to ensure good adhesion of the copper tape.

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 connection to the next bay of
material.

© BASF Australia Ltd, Page 53

Section D: Products

7.9.5 Mixing

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

Temperature is critical to the correct application of the UCRETE MF40AS. 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.

When discharged from the mixer the UCRETE MF40AS should be at least 18°C.

Mixing is critical for UCRETE MF40AS floors as incorrect mixing will adversely affect the antistatic
properties of the finished floor.

Suitable mixing equipment: Collomatic XM2 650 or similar

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

Unsuitable mixing equipment: High speed drill & paddle

Cretangle
Mixal
Pennine

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

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.

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.

Typically, 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).

7.9.6 Application

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

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

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.

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

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.

© BASF Australia Ltd, Page 54

Section D: Products
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:

• Expansion joints in UCRETE MF40AS 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.
• Care should be taken when installing joints not to damage the copper tapes within the floor
• 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.
• Late trowelling will sweep the pigment rich surface layer aside exposing the fillers below resulting in
variations in texture and colour shading.

© BASF Australia Ltd, Page 55

Section D: Products
7.10 UCRETE MT

Heavy duty polyurethane trowel applied floor finish

7.10.1 Packaging

Part 1 2.37 kg
Part 2 2.86 kg
Part 3 20.00 kg
Part 4 0.50 kg
25.73 kg net per unit

7.10.2 Coverage

4mm 10 -12 kg/m²

7.10.3 Planning

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 4mm floor 5 -7.5m for a single mix 9 -15m for a double mix

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

7.10.4 Priming

Ensure that PRIMER FS or UCRETE MF scratch coat has been correctly applied and cured.

The primer is necessary to prevent air rising out of the substrate causing defects in the finished floor.

You will not achieve the desired coverage rates on an unprimed floor.

7.10.5 Mixing

Temperature requirements: site temperatures 8 - 30°C, material temperatures 15 - 20°C Mix the material
in a forced action mixer as per section C
If using Fast Part 1 ensure sufficient manpower is available to apply properly within the potlife.

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

7.10.6 Application

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

Avoid over-trowelling as this results in gloss variations and impaired slip resistance.

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.

© BASF Australia Ltd, Page 56

Section D: Products
You cannot use the roller to flatten the surface of a poorly trowelled floor.

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.

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 user’s requirements.

Excessive use of the roller can lead to the inclusion of air into the surface of the floor, resulting in
pinholes.

© BASF Australia Ltd, Page 57

Section D: Products
7.11 UCRETE UD 200

Heavy duty polyurethane trowel applied floor finish

7.11.1 Packaging

Part 1 2.37 kg
Part 2 2.86 kg
Part 3 24.80 kg
Part 4 0.50 kg
30.53 kg net per unit

7.11.2 Coverage

6mm 12kg/m²
9mm 18kg/m²
12mm 24kg/m²

7.11.3 Planning

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

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

7.11.4 Priming

Ensure that PRIMER FS or UCRETE MF scratch coat has been correctly applied and cured. The use of
a UCRETE primer 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.

7.11.5 Mixing

Temperature requirements: site temperatures 5 - 30°C, material temperatures 15 - 20°C Mix the material
as per Section C. UCRETE UD200 is best mixed in a mortar mixer

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

If using Fast Part 1 ensure sufficient manpower is available to apply properly within the potlife.

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

© BASF Australia Ltd, Page 58

Section D: Products

7.11.6 Application

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

Avoid over-trowelling as this results in gloss variations and impaired slip resistance.

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.

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

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.

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.

© BASF Australia Ltd, Page 59

Section E: Special Techniques

8 SPECIAL TECHNIQUES

8.1 EARTHING ANTI-STATIC SYSTEMS

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

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
primer before the application of the antistatic bodycoat/layer. Please see the individual system
guidelines.

8.1.1 Earth Linkages

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

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.

An earth Linkage should be installed as follows

Figure 1 - Earth Linkage

a) 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.

b) Self-adhesive copper tape is then used to fix the fan of copper wire to the floor. The primer, whether
regular or scratch primer, should be abraded where copper tape is to be applied to ensure good
adhesion

c) The strips of copper tape that will extend in to the main floor are then placed over this area. Ensure good
contact is made between the copper tape and the multi strand wire.

d) If required this configuration can be glued into place with a conductive scratch primer (such as PRIMER
LCAS). Care must be taken to keep the thickness to a minimum so the connection will not be visible in
the finished floor.

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Section E: Special Techniques

8.1.2 Copper Tape Geometry

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

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.

With UCRETE anti-static systems no part of the floor should be more than 6m 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.

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.

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 x 15 m

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Section E: Special Techniques
Figures 3 - 5 1200m² room 20m x 60m

a) This will be applied in four bays. First the primer is applied on the initial area to be coated. The primer 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 primer 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.

b) The primer to the next area is then applied. When cured another “L” of copper tape is applied connected
at the top to the previous bay of material. This area is then coated.

c) Work then continues in the same way with the last two bays.

d) 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.

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.

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Section E: Special Techniques
Figure 6 - Using the same principles this is a plan for a more complicated area

The exact location of the tapes can be varied to suit the various 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.

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.

Recommended Copper Tape:

3M 1181 Tape. Copper foil with conductive adhesive 15mm wide

From 3M Electrical Products Division
www.3M.com

or
AT526 35 Micron Copper Foil Shielding Tape
From Advance Tapes International Ltd
www.advancetapes.com

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Section E: Special Techniques

8.2 Channels and Sumps

Rendered Channel see Section 5.5 above

UCRETE RG grade (primed with PRIMER RG) may be used for lining channels and sumps; apply 6 - 9
mm in one application

Fully lined Channel see Section 5.5 above

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.

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 18mm thickness of UCRETE UD200 is suggested for such applications. Brown parcel tape produces
excellent results as a release agent on shuttering.

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.

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.

Contact BASF for specific advice.

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.

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Section E: Special Techniques

8.3 Dairy Grids

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.

a) The dairy grids are 13mm in depth and, therefore, either require:
i) the concrete being eroded to accommodate the extra depth of the grid or
ii) the adjacent area of UCRETE ramped up to the grid to provide an even transition.

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

c) 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.

d) If a thickness of up to 5mm is required under the grids UCRETE UD200 can be used as a 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.

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

Recommended Grating

Thomas Dudley Ltd.: Grating F04750-200-AFC, Pattern D356, 305mm x 305mm x 13mm
www.thomasdudley.co.uk

Note:

For many of the areas where previously Dairy grids have been specified UCRETE IF is found to make an
excellent alternative specification which is easier, quicker and cheaper to install.

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Section E: Special Techniques

8.4 Repairing Previously Laid Ucrete Flooring

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

a) 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.

b) Remove the damaged UCRETE flooring using by hammer and chisel, taking care not to damage the
surrounding areas.

c) 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.

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

e) Prime the substrate as required with the appropriate UCRETE primer and allow to cure.

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

g) 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

f) Remove the masking tape after 1 hour.

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Section F: Health and Safety

9 HEALTH AND SAFETY

Reference is made to the material safety data sheets for each individual component.

The following specific measures must be observed.

9.1 Protective Equipment

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

9.2 Treatment of Spillages

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

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.

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

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. (1)(3) Transfer
to a container for disposal.

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.
(1)
Absorbent carrier - clean, dry sand or earth.
(2)
Liquid decontaminant - 5% solution of soda ash (sodium carbonate) in water.
(3)
Absorbent carrier and liquid decontaminant must both be readily accessible on site.

9.2.3 Part 3 for all UCRETE priming, flooring and vertical grades, Part 5 and all FILLER
grades

Ensure suitable personal protection during the removal of spillages. Contain spillages. Protect
against dust. Clean up spillages. Transfer to a container for disposal. Vacuum / wash the spillage
area clean.

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Section F: Health and Safety

9.3 Disposal

9.3.1 Part 1 and Part 4 for all UCRETE priming, flooring and vertical grades

Disposal 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.

9.3.2 Part 2 for all UCRETE priming, flooring and vertical grades and TOPCOAT PU CLEAR

Disposal 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.

Small 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).

Large quantities - destruction by controlled pyrolysis with scrubbing and neutralisation of the
vapours, using incinerators specifically designed for the destruction of noxious chemical waste.

9.3.3 Part 3 for all UCRETE priming, flooring and vertical grades, Part 5 and all FILLER grades

Disposal should be in accordance with local, state or national legislation. Bury on an authorised
landfill site or incinerate under approved controlled conditions.

9.4 Solvents

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 0718

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
Freecall: 1300 227 300 Freecall: 0800 334 877
www.master-builders-solutions.basf.com.au www.master-builders-solutions.basf.co.nz

© BASF Australia Ltd, Page 68