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DO NOT OPEN ANY PACKAGES or install this material until all
members of your crew have read and understand these instructions as well as
all relevant MSDS sheets. If you do not understand any part of these
instructions CALL EMSEAL: 800-526-8365 or 508-836-0280.
This document does not purport to address all of the safety
concerns, if any, associated with this product's use. It is the
responsibility of the user of this document to establish appropriate safety
and health practices and to determine the applicability of regulatory
limitations prior to use. The use of a dust mask, safety goggles and gloves
is recommended. Keep out of reach of children.
IMPORTANT: This product cannot perform its intended
function if not properly installed.
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1
Installation
Equipment & Storage
In addition to safety equipment required to comply with applicable
Federal, state and local safety regulations, equipment to prepare and
repair the joint-faces, as well as normal tools of the trade, the
following are required:
Equipment Checklist:
Tape measure
Mixing paddle and heavy-duty, low-speed drill for
mixing epoxy
adhesive
Caulking gun for 10-oz silicone tubes
provided
Long-bladed, serrated bread knife
Hacksaw
Miter box or miter block
Spray bottle with water
Duct Tape (2 ½ times the length of joint)
Spatula to scrape epoxy from can
Chemical resistant gloves
2-inch wide (50mm) margin trowels for applying epoxy adhesive on
joint faces
Caulk knives for tooling sealant bands
Toluene** for cleaning joint-faces, trowels and mixer
Clean lint-free, 100% cotton rags
Cold Days: Store Sealant, off the floor,
inside at above 68°F (20°F). It will recover slower when cold and
faster when warm.
Very Hot Days: Keep
sealant out of direct sun when the temperature is greater than 60°F (15°C)
until immediately prior to installation into joint.
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2
Prepare &
Solvent-Wipe Joint Faces
Concrete:
• Remove loose particles and weak concrete to ensure sound concrete
substrate. Spalls, chipped edges and uneven surfaces must be repaired
using suitable patching material and proper patching geometry and
techniques. Joint faces must be parallel.
• Joints must have unobstructed depth greater than or equal to the full
depth of the largest material supplied plus 1/2-inch (6mm).
• Remove all contaminants by sandblasting or grinding to ensure a
thoroughly clean and sound substrate for the full sealant depth.
NOTE: DO NOT use a wire wheel--this will polish the substrate and cause
bond-failure.
• Dry all wet surfaces.
NOTE: Do not use flame to dry substrate--this
will leave carbon on the substrate and cause bond-failure.
• Wipe joint faces with solvent-dampened, lint-free rags to remove all
concrete dust and contaminants.
Metal:
• Sandblast or grind to rough, white metal and solvent-wipe immediately
prior to applying HORIZONTAL COLORSEAL epoxy.
IMPORTANT: Ensure that no oxidation (rusting) occurs before the epoxy is
applied.
Other Substrates: Contact EMSEAL. |
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3
Measure Joint Width & Find Correct Size Material
• Measure joint width at deck surface and below to
ensure joint faces are parallel.
• Material has been supplied to suit your mean-temperature field
measured joint widths. Widths of material supplied are marked on each
stick of material. Find correct box and open it.
• Compare width of material supplied as marked on each stick against
mean joint width. Actual width of material as measured between hardboard
will be slightly less than marked size because material is over-compressed for ease of installation.
NOTE: If unsure of correct material selection, consult
EMSEAL.
IMPORTANT:
Do not
remove outer plastic packaging until you have read and understand the
rest of these instructions as material may expand prematurely. |
4
Start with Universal-90 Installation
Changes in plane, either up or down, require the use of
factory-fabricated Universal-90’s from EMSEAL.
Sequencing: Install factory-fabricated transition
and/or termination pieces first. Connect straight run material to
in-place terminations and transitions.
Note: If installing very long
runs of material, to avoid having to work at distant ends of a joint run
and in order to prevent epoxy from fully curing, the final
factory-fabricated Universal-90 termination can be installed as the
second-to-last piece.
Cut closing pieces 3/8-inch
(10mm) longer than the opening to be joined. Compress material
longitudinally to fit.
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5
Mask Deck & Mix Epoxy
Adhesive
•Using duct tape, tape off the deck on both sides of the
joint.
Mix Epoxy
•EMSEAL epoxy adhesive may be used in the 40°F (5°C) to 95°F (35°C)
temperature range.
•Using a trowel, transfer the entire contents of Part B (hardener) into
the contents of Part A (base).
•Mix the material thoroughly with a drill and mixing paddle. Scrape the
walls and bottom of the container to ensure uniform and complete mixing.
•Always mix component B (hardener) into component A (base). Ensure that
a uniform gray color with no black or white streaks is obtained.
IMPORTANT:
DO NOT thin the epoxy.
PRECAUTION: Wear chemical-resistant gloves and/or barrier hand
cream when handling liquid sealant or epoxy. Remove promptly from skin
with a commercial hand cleaner before eating or smoking. Avoid inhaling
vapors.
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6
Apply
Epoxy to Substrate, Unwrap HORIZONTAL COLOSEAL
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Ensure that the mixed epoxy adhesive is applied to
the substrate before the pot life has expired (10 - 30 minutes
depending on the ambient temperature).
WARNING:
Epoxy will harden more quickly when left in the pot. Apply it onto the
joint face as soon as possible.
IMPORTANT: The epoxy must still be uncured when
installing HORIZONTAL COLORSEAL foam into the joint-gap.
If the epoxy cures before installing the HORIZONTAL
COLORSEAL foam
then reapply new epoxy. If work is interrupted for more than 2 hours
after initial cure then grind the old epoxy and apply new wet epoxy.
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IMPORTANT: While one or more workers are applying
epoxy to the joint faces, others must prepare the
HORIZONTAL COLORSEAL foam. The
foam is kept under compression by plastic wrapping and
hardboard on both sides.
• Slit the plastic packing by cutting on the
hardboard and remove hardboard and inner release liner. DO NOT cut
along the silicone bellows face.
IMPORTANT:
Work quickly
and deliberately after cutting the shrink-wrap to avoid material
expanding beyond a usable size. |
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7
Wipe
Release Agent off Silicone Facing
•
For packaging and production reasons, the silicone facing is coated in
the factory with a release agent.
• Prior to installation, this agent must be wiped off in
order for the injected sealant bands described in Step 10 to adhere to the
silicone facing and to avoid contamination of the substrate at this
point.
• Lightly, quickly and thoroughly wipe the cured silicone facing with a
lint-free rag made damp with water to remove the release agent.
TIP: Use the hardboard packaging as a flat, clean working surface. |
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8
Install First HORIZONTAL COLORSEAL Foam Length into Joint & Apply Silicone to Bellows
Face
• When installing the
foam into the joint, ensure that epoxy on the joint face has not cured.
• When installed, the HORIZONTAL COLORSEAL must be recessed so that the top of the
bellows is flush or slightly below the deck surface.
• Note: When material is correctly expanded for a snug fit it will
support its own weight in the joint.
• Feed material into joint, starting from one end. The material should
fit snugly and must be eased into the joint with steady, firm pressure.
• Leave the end to be
joined to the next length sticking slightly proud of the joint.
• Repeat step #7 for each new stick.
• On the end of the next
stick, using a bulk gun and
the sausages of silicone provided, apply the liquid silicone to the
exposed face of the silicone bellows. Avoid spreading silicone
sealant to foam face. |
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9
Install Next Length. Repeat.
• Work
in one direction towards the previously installed length or end of
joint. Do not stretch material.
• Leave the end to be joined to the previous length sticking proud
of the joint--push the joining faces together.
• Push Hard on the stick to compress joins firmly together. Ensure
there are no voids at joins.
• Once the full length is installed, push the protruding join into
the joint and tool off the excess silicone.
• During low temperature installation, provide as much ambient heat
as possible around installed foam to accelerate recovery. |
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10 Inject
Silicone Sealant Bands at Substrates & Tool Excess Silicone
• Wipe any excess epoxy from top of material using a
clean rag.
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• Before the
epoxy cures, force the tip of the silicone bulk gun between the
substrate and the
HORIZONTAL
COLORSEAL foam. Inject a 3/4-inch (20mm) deep silicone sealant
band between the foam, cured silicone facing and the joint-face.
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• Tool the freshly applied silicone firmly to blend with
the substrates and cured silicone facing, and to ensure a proper bond
and seamless appearance.
• Where the foam meets at butt joins, tool the excess silicone that
squeezes out from the top and between the bellows.
IMPORTANT: Silicone left between the wrinkles of the
bellows could constrain movement--using a caulk knife, remove excess
sealant and blend what remains into the bellows.
• Note: Silicone sealant band is only applied to the top
side of the foam.
Clean Up: Remove epoxy and
silicone sealant from equipment before it cures using MEK**,
Toluene**, or Xylene**. These solvents are not effective after the
epoxy or silicone has cured. Cured material may be removed by
cutting it away with sharp tools or sandpapering.
**(Solvents mentioned or referred to are toxic and flammable.
Observe solvent manufacturer’s precautions and refer to Material
Safety Data Sheets as well as local and federal requirements for
safe handling and use).
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11
Transitions, Ends,
Direction
Changes, and Special Conditions
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Sequencing: Install factory-fabricated transition and/or
termination pieces first. Connect straight run material to in-place
terminations and transitions. Apply the joining silicone (at the
bellows ends only) on the straight length before inserting it into
the joint (see step #8). Bring the join firmly against the butt end
of the already installed Universal-90 and push the straight run
stick towards this join throughout the process of installing it.
Note: If installing very
long runs of material, to avoid having to work at distant ends of a
joint run and in order to prevent epoxy from fully curing, the final
factory-fabricated Universal-90 termination can be installed as the
second-to-last piece.
Cut closing pieces 3/8-inch (10mm) longer than the opening to be
joined. Compress material longitudinally to fit.
UNIVERSAL-90 TRANSITIONS
• Universal-90’s are designed to continue HORIZONTAL
COLORSEAL
through changes in plane such as at floor-to-walls, curbs, treads
and risers, or other such changes in slab thickness. Unlike
straight-run lengths, BOTH sides of Universal-90’s are silicone
coated with bellows so there is no top or bottom. They can be turned
over to be used either as an upturn or a downturn. Install
factory-fabricated transition and/or termination pieces first.
Universal-90’s may also be used to transition to another EMSEAL foam
product.
• Connect straight run material to in-place terminations and
transitions (see step #8). Cut closing pieces 3/8-inch (10mm) longer
than the opening to be joined. Compress material longitudinally to
fit.
UNIVERSAL-90 TERMINATIONS
• When HORIZONTAL COLORSEAL does not run in a closed loop it needs to
be terminated with a factory-fabricated Universal-90.
• Prepare gap with epoxy adhesive in the same
manner as HORIZONTAL COLORSEAL sticks. As with Universal-90 transitions, install
factory-fabricated transition and/or termination pieces first.
• Connect straight run material to in-place terminations and
transitions (see step #8).
• Cut closing pieces 3/8-inch (10mm) longer than the opening
to be joined. Compress material longitudinally to fit.
• The factory-sealed end acts as the termination and points
up or down to best block or direct water flow.
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FLAT CORNERS:
• Work towards the corner so that the last two
pieces to install will join at the corner.
• Cut each piece to be joined 3/8-inch (10 mm) longer than needed.
• Install one piece so that it runs through the intersecting
joint-gap. Firmly push and compress the extra length so that a tight
fit in the corner is achieved.
• Coat the exposed butt ends of the bellows with liquid
silicone
sealant provided as shown in Step 8. Firmly butt intersecting pieces into sides of
already placed material.
IMPORTANT: Be sure that there is no epoxy on the sides or faces
of foam at a butt join.
• Using a caulk knife, remove any excess sealant and blend the
liquid silicone into the bellows to preserve the bellow shape.
NOTE: The extra length will make it a tight
fit--this results in a compression fit.
• Inject a bead of liquid silicone where the silicone faces join and
where the silicone faces meet the substrate.
CROSSES and TEES:
• Run one piece of material across the intersection.
Coat the exposed butt ends of the intersecting bellows with liquid
silicone
sealant provided as shown in Step 8. Firmly butt intersecting pieces into sides of
already placed material.
• Using a caulk knife, remove any excess sealant and blend the
liquid silicone into the bellows to preserve the bellow shape.
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IMPORTANT: Be sure that there is no epoxy on the sides or faces
of foam at a butt join.
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SILICONE-COAT ANY EXPOSED FOAM ENDS
IMPORTANT: If HORIZONTAL COLORSEAL runs are not part of
a closed loop system, and Universal-90 terminations are not used (run
does not terminate in an upturn or downturn), lightly coat any exposed
foam ends using the liquid silicone sealant provided. This is critical
in ensuring that the watertightness of the foam is sealed. |
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