Santex is a
sand filled epoxy system for use as a troweled industrial floor base, a troweled
floor topping for leveling or sloping or as a concrete patch or repair mortar.
Typical uses include such applications as concrete spall repair, drainage
correction to fill 'Standing Water' low areas, ramping from a lower to a higher
area, filler material, troweled cove base, etc. The system is made up of fine
silica sand and larger coarse sand mixed at a ratio of 3 parts fine to 2 parts
coarse (sand samples available). This mixture has several advantages and allows
for easier troweling. Aggregate to epoxy ratios vary from generally 6 : 1 to 9 :
1 respectively depending on the application. Several epoxies can be used to achieve
the desired solid state properties but whatever the choice; it should be a low
viscosity epoxy system in order to wet the sand evenly and thoroughly. The
choice of epoxy is determined on the characteristics required of the cured
product to best suit the needs of the application from rigid to flexible or some
point in between. The epoxy's open time and cure time are also factors to
consider for proper selection.
(A) IG-3 Epoxy will give
an extremely rigid high strength product with a fast rate cure.
(B) SB-30 Epoxy will give a strong 25% elongation product with a moderate rate
(C) IG-100 Epoxy will give a moderately flexible product with a slow rate of
Cured Santex Systems are available with a compressive strength from 800 psi to
17,500 psi and a tensile elongation from 3 % to 110 %. Cure times will allow for
foot traffic from 2 hours to 72 hours. It should also be noted that the heat
distortion factor of the product must be considered in certain applications.
Selection of proper mixer and batch size is also important to consider for good
6 cups of the
mixed Parts 'A' and 'B' epoxy components at the systems mix ratio blended with
1.5 gallons of fine sand and 1 gallon of coarse sand creates a good workable
batch that will cover 6.5 square feet at a depth of 1/2 inch.
require a primer and a sealer coat in order to be properly applied. A gallon of
sand will have air as approximately 1/3 of
its volume due to porosity. The liquid to aggregate ratio
of the Santex System must maintain properties that allow it to be troweled and
this means it will be porous. By troweling the
Santex into a wet primer, the porosity of the system is eliminated on the bottom
of the overlay. Primer epoxy selection can also be different than the Santex
epoxy selection to allow for extended primer cure time and/or solid state
property characteristics to allow for more control and better bonding. This is
most useful in specialized applications.
The need for a high
strength rigid Santex overlay on concrete exposed to thermal shock
and contraction considerations.
Santex Systems require a sealer coat to keep the overlay from
having a porous finish. Depending on the version of the Santex System used, multiple
sealer coats may be needed. There are very few applications where a porous
Santex overlay would be desired; therefore the sealer coat application is the
normal application technique. Sealer epoxy selection can also differ from the Santex
epoxy selection to suit the requirements of the application.
For example: The use of Santex System
to ramp a step from one room in a shop to another room in order to be able to
roll wheeled carts, engine hoist, tool boxes, etc. between the two rooms. The
TC-200 epoxy can be used as the sealer epoxy to match the overall floor system.
Colored sand or quartz aggregates can be used with a clear
sealer epoxy such as the FS-190 epoxy to create a more decorative use in special
applications for the Santex System.
Directions: A clean, dry, solid
surface is essential to apply the Santex System onto for permanent results. Due
to the various applications possible, consult with Precision Epoxy for proper
substrate preparation for your particular project.
Primer: The Santex mix
must always be applied into a WET primer. This means a wet primer. If the
concrete is overly absorbent where the primer soaks in leaving a dry look or
feel prior to applying Santex - - Re-Prime; If the primer is applied too
far ahead of the trowel mechanic applying the Santex and tacks out before the
Santex is applied - - Re-Prime. It is important to prime solid, for
example; in a spall repair application where the surface has been chipped away
of flaking concrete to a solid surface that is very uneven, then apply the
primer with a thick 3/4 to 1 inch nap roller cover to coat evenly and properly.
Santex: Select the type of
epoxy binder to suit the project requirements. Mix Parts 'A' and 'B' of the
selected Epoxy System at the proper mix ratio for 2 to 4 minutes depending on
batch size. Then add fine/course sand blend and mix until sand is completely wet
and saturated with epoxy (2 to 4 additional minutes). Scrape sides and bottom of
mixing container while mixing to avoid having any dry sand in the batch. Dump
blended Santex mix into wet primer on the prepared area and trowel to desired
shape and/or thickness. Santex is allowed to cure overnight.
Sealer: Select the type of
epoxy to seal the cured Santex to achieve the proper surface strength and finish
to suit your application and to eliminate any porosity. In most
applications the sealer will need to be applied in 2 coats.
Santex pricing is determined by square footage and material depth. It is very
difficult to estimate because you are generally dealing with cubic volume on an
uneven surface. This situation is next to impossible to measure with any degree
of accuracy; if you cannot estimate, you simple have to guesstimate.
Coverage example: One batch at 6.7
to 1 ratio of aggregate to epoxy respectively would use 2.5 gallons (33 lbs) of
sand blend and 48 fluid ounces (6 cups) of epoxy. This batch covers 13 square
feet at 1/4 inch thick which equals 34.5 square feet per gallon of epoxy and
39.5 square feet per 100 lbs of sand blend. Epoxy to aggregate ratios can vary
to suit the needs of the application and/or the epoxy binder selection.