Asian Paints Smartcare waterproofing methodology & work details


USING ASIAN PAINT’S SMARTCARE PU MAGNUM US & SMARTCARE PU INSULATOR & Damp-proof Ultra + Screed

 

 

1.0 MATERIALS SPECIFICATION REFERENCE

This Method Statement is to be read in conjunction with relevant documentation.

 

1.    Please refer to PIS of the relevant products mentioned in this method Statement

2.    Safety Data Sheets

3.    Relevant Application Instructions if any from the Manufacturer

2.0 MATERIAL REQUIREMENTS

The materials needed for to complete the tasks set forth in this method statement are:

 

1.    Smartcare PU Ultron

2.    Smartcare Epoxy Primer

3.    Smartcare PU Insulator

4.    Smartcare PU Magnum

5.    Closed Cell Backer Rods for Joints and deep cracks

6.    Smartcare Hybrid PU sealant

7.    SmartCare GP Grout/Micro Concrete

8.    Smartcare Repair Polymer

9.    SC Vitalia Neo

10.  Silica Sand: 0.3 to 2 mm in grain size

11.  60 Gsm non-woven geotextile for crack & change of plane treatment

12.  150-200 Gsm Geotextile fabric to use as a separation layer

 

3.0 GENERAL APPLICATION PARAMETERS

Condition

Limitation

Ambient Temperature

> 5 to 40 C

Humidity

< 80%

Substrate Moisture level

Moisture Level for Smartcare PU Magnum US application to be less than 4%  

Minimum Compressive Strength of Substrate  

20 MPa

Pot Life at 25 C

Approx. 25 minutes

 

4.0 MANDATORY APPLICATION TOOLS AND SERVICES

The applicator shall have at the minimum, the following tools for suitable application of Smartcare PU Ultron.

 

§  Airless Proportionating 1 Component Spray Machine, Plural machine

§  High Pressure Water Jetting [> 160 bars]

§  Hammer / Jack hammer

§  Chisels

§  Grinders and accessories

§  Wire brush & Other Cleaning tools

§  Air blower

§  Jiffy Mixer [handheld]

§  Roller / Brush / Squeeze

§  Substrate Moisture Meter / Thermometer / Humidity Gauge

§  Safety Helmet / Vest Reflective Jackets / Safety Shoes

§  Rubber Hand Gloves / Mask

§  Wet film thickness gauge

§  Mechanical Stirrer

§  Graco XP2

§  PPE’s for personnel

 

SERVICES:

 

Main Civil Contractor shall hand over to the Specialist waterproofing applicator, the substrate in a cleaned condition free from water, grease, oil, surface defects, debris, dirt, or any other depositions. The main civil contractor shall also provide necessary lifting arrangements for any equipment / materials and shall also provide a covered storage area for materials. The main Civil Contractor / Owner shall provide water and electricity, at site at no charge.

 

 

5.0 KEY SITE REQUIREMENTS

WORK SCHEDULE:

Specific requirements for Schedule to be agreed upon mutually between the specialist waterproofing applicator and the main civil contractor so as to meet the overall project schedule.

 

 

SITE SAFETY REQUIREMENTS:

The main civil contractor shall make provisions for the following safety accessories / appurtenances:

 

§  Eye Wash station

§  First Aid Station

§  Respirators for Special Applications

§  Protective Aprons

 

PERSONNEL REQUIREMENTS:

 

Applicator Qualifications: Shall be trained and approved by the manufacturer for the application of the system specified. The applicator firm should have at least 10 years’ experience in successful skilled application of Polyurethane based waterproofing systems with airless spray machine.

 

Supervisor Qualifications: Shall be trained experienced and capable of handling spray applied waterproofing systems, should have supervised cold application of Polyurethane based waterproofing systems with airless spray machine / Roller / Brush application, for at least 2 years.

 

Technician Qualifications: Should be trained by the manufacturer for the application of the system specified.

 

 

6.0 METHOD OUTLINE

The application of Smartcare PU Ultron should follow the general procedure as outlined in this section:

 

1.    Surface Preparation

2.    Repair of the substrate to provide an even / stable substrate

3.    Repair of Surface Cracks / Construction Joints

4.    Repair of Moving Cracks if any

5.    Treatment of Horizontal / Vertical and Vertical / Vertical Interfaces using Smartcare PU Sealant

6.    Application of the Smartcare PU ultron

7.    Termination

8.    Curing

9.    Protection System

 

 

7.0 DETAILED METHODOLOGY

 

Pre-Pond Test:

 

  • Ponding Test should be done for min 48 hrs by filling water up to 50- 75 mm depth to ensure that there are no leakages observed.

 

Injection Grouting, if required:

 

  • If leakages are observed during pre-pond testing, then using low viscous epoxy Injection grouting for treating leakage point. After identification of leakage point, injection packers should be drilled up to 25-30mm depth and using low viscous epoxy grouting for treating the leakage point.

 

 

 

 

 

SURFACE PREPARATION:

 

·         Prior to waterproofing installation, arrange a visit to project site with representative from the manufacturer. Representative shall inspect and certify that concrete surfaces are in acceptable condition to receive waterproofing treatment.

·         Surface to be waterproofed will be dry concrete, cementitious surface, tiled surface or dry treated shall be clean, sound and free of all contaminants which may interfere with adhesion or proper curing of the membrane. If release agents are present, they must be removed prior to the application of Smartcare PU Magnum US.  

·         Concrete substrate should be light steel trowelled followed by a fine hair broom or equivalent finish achieving a slightly rough concrete surface profile similar to that recommended in ICRI CSP 2-5. Concrete surface shall be free of voids, exposed aggregate areas, honey combs, splatters, ridges, fins and other projections or depressions which preclude a smooth and level surface.

·         All reinforcing, including cut off rebar, shall be covered by a minimum of 20 mm of concrete, epoxy or approved repair mortar.

·         Concrete masonry unit construction may receive a plaster coat of acceptable cementitious coating approved by manufacturer. All CMU walls must have all joints solid grouted and struck flush with no voids.

·         For horizontal applications, follow good drainage practice to permit unimpeded water flow to drain(s) number sufficient to allow water to thoroughly evacuate the membrane surface.

·         All penetrations shall be encased in concrete. Penetrations must be solid grouted in place. No flexible pipe or corrugated pipe of any type shall be used for a through slab penetration. Penetrations shall be spaced a minimum of 5 cm apart to allow for detail work around penetration.

 

REPAIR OF THE SUBSTRATE:

 

·         Examine surface to be waterproofed for form tie holes and structural defects such as honeycombing, rock pockets, faulty construction joints and cracks. Such defects should be repaired in accordance to the following procedure.

·         In case of highly damaged / cracked / weak substrates and construction joints, a site engineered epoxy mortar should be prepared by mixing 3 part of Magnum Primer Hardener Part A: 1 Part of Epoxy primer resin: 3.5 -4 Parts of Silica Sand to repair holes, honeycombing, construction joints etc.

·         If only surface cracks and moving cracks are encountered, the procedure to repair them is covered under sections 3 and 4 below.

·         Active water ingresses / leaks, should be protected ensure no water is spilled over the surface to be treated prior to application

 

 

Repair of Surface Cracks < 1.0 mm

 

·         Surface cracks greater than 0.3mm and less than 1.0 mm width can simply be coated with two coats of Smartcare PU Magnum US sandwiched 60 Gsm non-woven geotextile, the coating extended to 75 mm on either side of the crack.

·         Opening the cracks which is less than 1mm, if any, in V/U shape using electrically operated cutting machine. Cleaning the surface thoroughly from dust and loose particles using wire brush and air blower. The same shall be sealed/filled with SBR mortar admixed with AP SC Multipurpose polymer/Repair Polymer at the ratio of 1:3:5%(Cement + sand + 5% polymer of Asian Paints Multi-Purpose polymer or equivalent) and pre stripping the cracks with 40 gsm geofabric/40 gsm fiber mesh with AP SC PU Magnum US by extending 50 mm on both the sides of crack.

·         Apply epoxy primer and after drying, minimum Two coats of Smartcare PU Magnum US sandwiched with 60 gsm non-woven geotextile, the coating extended to 75 mm on either side of the crack.

 

 

Repair of Surface Cracks > 1.0 mm and Construction Joints

 

·         Wider cracks (> 1.0 mm) should be routed out to 6 mm wide by 12 mm deep.

·         Clean the groove using water jet / air blower to remove dust, dirt etc,

·         If any crack found more than 1mm then treatment shall be done with Low viscous epoxy grouting (same shall be paid separately) and pre stripping the cracks with 40 gsm geofabric/40 gsm fiber mesh with AP SC PU Magnum US by extending 50 mm on both the sides of crack

 

Repair of Moving/Dynamic Cracks:

 

·         Chip out & Remove the old filler material from the affected area.

·         Clean the surface with the help of air blower to remove the dust and loose particles.

·         The sausage should be inserted in hand operated application gun and nominal pressure has to be applied over the trigger of the gun so that sealant starts extruding out of the nozzle & filled in the joints. A slightly excess amount to be applied for tooling and finishing purpose.

·         Spread at edges to ensure adhesion of sealant at both edges of joint/ crack and then level the sealant with spatula/ putty knife.

·         Allow the sealant to cure for 24 hours to achieve its full strength.

·         Clean and wipe the existing coating with solvent (Xylene/Acetone) 75mm either sides of crack.

·         Apply epoxy primer, after drying time apply minimum Two coats of SmartCare PU Magnum US at a dosage of 0.750 – 0.80 Kg/Sqm/coat, sandwiched with wet/dipped 60 GSM non-woven geotextile/EPDM Tape, fixing and application of coating shall be extended to 100 mm on either side of the crack.

·         Step 1 – After solvent cleaning Apply a coat on the existing coating extended 75-80 mm both the sides of cracks.

·         Step 2 – Dip the 100/150 mm wide tape into the mixed solution bucket.

·         Step 3– Fix the geotextile/epdm fleece snugly & uniformly impregnates on the wet coating extended has to be stretched at both sides in equal width.

·         Step 4 – Apply one more coat of PU Magnum US over it at a dosage of 0.75-0.80 kg/Sqm extended 100 mm at both sides to fully encapsulate the membrane in the coating.

 

 

Treatment of Construction Joints / Change of Planes (With SC AP GP Grout)

 

SURFACE PREPARATION:

·         Clean the substrate surface and remove loose concrete, dust, oil, paint, grease, waterproof coating etc. If the concrete surface is defective or has laitance, it must be cut back to a sound base. The old concrete substrate should be saturated with clean potable water for several hours. Make sure before SmartCare GP Grout/Micro concrete is poured, free water from the surface and the formwork must be removed. Apply bonding agent if required.

 

MIXING 

·         A pan mixer should be used so that a homogeneous concrete mix is obtained. Charge approx. 80% of the total required water i.e. 2.6 - 3 litres to pan mixer, start addition of powder slowly under continuous mixing. After complete addition of powder, check the flow and add remaining 20% water i.e. 0.65-0.75 litres (Note – Check for bleeding, if bleeding occurs over all water content has to be reduced) and mix for 2-3 minutes to get a homogeneous free flowing, uniform & lump free mix. Total water required: 3.25 to 3.75 litres per 25 kg bag i.e., 14+/-1% of the weight of powder. Make sure that for a 25 kg bag volume of water should not exceed 3.75 litres. Water that is added should be clean and potable.

 

PLACING

·         Pour the homogeneous mixture of SmartCare GP Grout/Micro concrete into a watertight shuttering. Post removal of the formwork cure the repaired concrete for minimum 5- 7 days by sprinkling water regularly.

 

·         Allow the fillet/groove material to dry, after drying apply epoxy primer and then after drying time, 2 coats of Smartcare PU Magnumn US to a minimum band width of 150mm to a consumption of minimum 1.6 kg/sqm in two coats and embedding 60 Gsm Geotextile Fabric in between the coats, prior to coating of entire area.

 

COVING/WATTA:

 

·         Providing and laying Angle fillet/Coving 75mm x 75mm at all vertical/horizontal junctions with 1:4 Cement/Sand mortar admixed with SmartCare Repair polymer @ 5 kg per 50kg bag of cement. (Mixing ratio for Coving: 1 cement: 4 Sand: 0.1 Repair polymer).

·         And pre-stripping to be done with 60 Gsm non-woven geo-textile with applying 2 coats SC Ultra Block 2k in both horizontal and vertical junctions in the tanks or equivalent coating.

 

EXPOSED REINFORCEMENT TREATMENT:

·         Should be treatment with non-shrink grout Asian Paints General Purpose Grout by cutting the exposed rod up to 15-20mm down, apply bond coat with Cement-Polymer slurry and then fill the same with grout material.

 

BORE PACKING: 

 

·         Core cut holes, cut out area, filtration plant etc., must be grouted with non-shrink cementitious grouts before the waterproofing coating is taken up for application.

·         Before the bore packing, surface of the PVC /MS pipe and concrete surface will be made rough and sand will be sprinkled with polymer bonding agent Smartcare Multipurpose polymer admixed with cement @ 1:1.

·         After 10-15min when bond coat is in wet condition fill non-shrink Smartcare General Purpose Grout admixed with 0.15 W/P ratio for 25Kg bag.

·         Further the treatment shall be covered into the coating with prestripping.

 

APPLICATION OF THE PRIMER:

·         Components A (resin) and B (hardener) are packed in two separate containers, having the correct predetermined mixing ratio by weight. The whole quantity of component B is added into component A. The two components should be mixed for about 2-3 minutes with a low-speed mixer (300 rpm), until the mixture becomes uniform. It is important to stir the mixture thoroughly near the sides and bottom of the container, to achieve uniform dispersion of the hardener. Then add equal quantity of water (30% by weight of primer) and continue mixing to ensure that the mixture obtains the desired workability

·         Apply the product using a Roller @ 200 - 400 Gms/Sq.m consumption. If the substrate is porous apply a second coat of primer after 4 hours and before 6 hours of 1st application coating.

 

 

 

 

APPLICATION OF THE SMARTCARE PU Ultron: (2.25 Kg/Sq.m for 3 coats for 1.5mm DFT)

·         The drum component should be mixed for about 3-5 minutes with a low-speed mixer (300 rpm), until the mixture becomes uniform. It is important to stir the mixture thoroughly near the sides and bottom of the container, to achieve uniform dispersion of the hardener.

·         Check the moisture of Surface to be coated, the moisture content of substrate should be < 4%.

·         Apply 1st coat of Smartcare PU Ultron using a roller or airless spray @ a consumption of 0.8 Kg/Sq.m on primed substrate.

·         After 6 hours and within 12 hours of 1st coat application of Smartcare PU Ultron, apply the second coat of Smartcare PU ultron using roller or airless spray @ a consumption of 0.80 Kg/Sq.m

·         After 6 hours and within 12 hours of 1st coat application of Smartcare PU ultron, apply the second coat of Smartcare PU Ultron using roller or airless spray @ a consumption of 0.70 Kg/Sq.m

 

 

APPLICATION OF THE SMARTCARE PU Ultron AT DAY LAPPING JOINTS:

 

·         Where a new waterproofing of Smartcare Ultron is joint to previous day coating of Smartcare PU Ultron at day joints, a new application will be lapped into existing by minimum 100-150 mm.

·         Where existing cured membrane of Smartcare PU Ultron is done 24 hours prior or surface is contaminated by dust, dirt etc, minimum 100-150 mm of Lapped end will be cleaned using cleaning agent – Acetone or Xylene solvent.

·         Allow the surface to dry and after that apply Smartcare PU Ultron as per procedure listed in Section: application of Smartcare PU Ultron.

 

 

TERMINATION:

 

·         Termination shall end after Floor Finish Level + 400 mm minimum.

·         Vertical: Enveloping system over parapet wall and terminating the coating into a groove of 5mm x 5mm. The groove will be sealed by using sealant / Epoxy mortar depending upon site requirements.

 

CURING:

 

·         Allow the SmartCare PU Ultron to cure to a firm rubber, [Min. 24 hours at 23 °C, 50% RH], the coating achieves full cure in 2-3 days.

 

SPRAY POLYURETHANE FOAM APPLICATION SC PU INSULATOR:

 

·         The spray polyurethane foam components (A) and (B) shall be processed in accordance with the manufacturer’s instructions.

·         The polyurethane foam shall be sprayed within the manufacturer's guidelines for temperature, humidity, and other atmospheric conditions please refer PIS.

·         The polyurethane foam shall be sprayed in minimum 1/2-inch-thick passes (lifts) with the overall thickness to be a minimum of 40 mm. The full thickness of spray polyurethane foam to be applied with any given area in same day.

·         Moisture Level for SmartCare SPUF application to be less than 4%.

 

 

INSULATION:

 

·         Application of SmartCare PU Insulator shall be sprayed in two components (a polyol and an isocyanate) that when mixed expand their volume to form a seamless layer. Within minutes this foam can be walked on and cures to 90% of its full strength in 4 hours.

·         It is better to apply in two-three layers to achieve desired thickness of Avg.50mm on horizontal surface only. Try and achieve Initial layer thickness 1.5-2.5 cm to achieve good adhesion.

·         It shall be done only for horizontal surface.

 

KEY CHECKS BEFORE PU INSULATOR:

 

·         Surface temperature range for PU spray foam application shall be 12 – 40 Degrees (Check with temperature sensor).

·         Wind speed should be not more than 30 Km/h.

·         Minimum thickness: 40 mm.

 

PROTECTION: PU Magnum US

 

·         Components A (resin) and B (hardener) are packed in two separate containers, having the correct predetermined mixing ratio by weight. The whole quantity of component B is added into component A. The two components should be mixed for about 2-3 minutes with a low-speed mixer (300 rpm), until the mixture becomes uniform. It is important to stir the mixture thoroughly near the sides and bottom of the container, to achieve uniform dispersion of the hardener. Then add equal quantity of water (30% by weight of primer) and continue mixing to ensure that the mixture obtains the desired workability

·         Apply the product using a Roller @ 200 - 400 Gms/Sq.m consumption. If the substrate is porous apply a second coat of primer after 4 hours and before 6 hours of 1st application coating.

 

 

 

 

APPLICATION OF THE SMARTCARE PU Magnum US : (1.6 Kg/Sq.m for 2 coats for 1.2 mm DFT)

·         The drum component should be mixed for about 3-5 minutes with a low-speed mixer (300 rpm), until the mixture becomes uniform. It is important to stir the mixture thoroughly near the sides and bottom of the container, to achieve uniform dispersion of the hardener.

·         Check the moisture of Surface to be coated, the moisture content of substrate should be < 4%.

·         Apply 1st coat of Smartcare PU Magnum US using a roller or airless spray @ a consumption of 0.8 Kg/Sq.m on primed substrate.

·         After 6 hours and within 12 hours of 1st coat application of Smartcare PU Magnum US, apply the second coat of Smartcare PU Magnum US using roller or airless spray @ a consumption of 0.80 Kg/Sq.m

.

 

 

Application Process for Vertical surface –

 

 

Step 1 – Epoxy base primer

 

·         The drum component should be mixed for about 3-5 minutes with a low-speed mixer (300 rpm), until the mixture becomes uniform. It is important to stir the mixture thoroughly near the sides and bottom of the container, to achieve uniform dispersion of the hardener.

·         Check the moisture of Surface to be coated, the moisture content of substrate should be < 4%.

·         Apply 1st coat of Smartcare PU Magnum US using a roller or airless spray @ a consumption of 0.8 Kg/Sq.m on primed substrate.

.

 

Consumption : 1.6kg/sqm

 

PRECAUTIONS

Do not apply during rains or extreme temperatures.

Avoid abuses which may lead to puncturing of membrane.

Ensure that the product is applied at least 6 inches inside the drain pipe.

For best results, apply parapet to parapet to envelope the entire building.

 

Protection System:

·         After drying of the coating, the same shall be covered with Non-Woven geotextile sheet of 200-250 GSM as a separation layer followed by PCC screed to slope.

  • Laying minimum 50 mm thick screed to slope at drainage point protective screed of M20 grade concrete admixed with 100% virgin polypropylene fibres @ 0.9 Kg per Cu.M adding up SC Vitalia neo Integral Wp compound @ 200ml/bag of cement, maintaining the slope 1:100 towards the drain point as per drawing. Concrete to a broom finish, well compacted, curing for 7 days etc. complete.
  • The screed shall be raised to the wall in form of Watta/coving to form a smooth corner.

·         The screed shall be further divided into panels of 4m X 4m with 10mm wide and 25mm deep control grooves, the same shall be filled with backer rod followed by filling of SmartCare Hybrid PU Sealant.

·         Make angle fillets all around the periphery of the wall and pedestals (if any) with polymer modified mortar with required curing.

.

 

 


8.0 COVERAGE / CONSUMPTION

Epoxy Primer: 200-400 Gms/Sq.m

PU Ultron :  2.3 Kg/sq.m (minimum two coats recommended).

PU Insulator: 3 Kg/Sq.m (minimum two – three coats recommended to achieve required thickness).

PU Magnum US : 1.6 kg/sqm

 

9.0 CLEAN UP

Clean up tools and machinery using recommended solvent.


10.0 QUALITY OF APPLICATION

The applicator shall conform to all precautions and quality control systems to ensure correct application of the material in question. These include:

 

  1. Quality Substrate Preparation
  2. Following Manufacturer Guidelines on Mixing, Application and Curing
  3. Quality Control of Materials
  4. Safety

For any further clarifications / assistance please contact local team

 

Methodology will change based on site condition and after manufacturer approval.

 

















Data sheet links: 

SC Pu insulator : https://drive.google.com/file/d/1e5SYFyj5Na5pTbbGh5b1r-bdCejI6k9M/view?usp=drive_link

Smartcare Bathroom Membrane : https://drive.google.com/file/d/13Ov5E5GoeEtKL7nwOFRfmoRnj96uAkMJ/view?usp=drive_link

Smartcare damp2K : https://drive.google.com/file/d/1_-QVw_KdZt4vwoiYEK3Xrm8Q4HtvitRU/view?usp=drive_link


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WACT APM Terminal Office Onne Port Harcourt Nigeria

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 PROJECT: Corporate Office Fit-Out – WACT, Nigeria 📍 Location: Onne, Rivers State, Nigeria 🏗️ Client: APM Terminals (WACT – West Africa Container Terminal) 📅 Duration: 4 Months 📐 Scope: Interior Fit-Out | Civil | Electrical | Furniture | HVAC Integration As the Quality Manager for the West Africa Container Terminal (WACT) office interior project, I oversaw the completion of a 45,000 square foot workspace in Port Harcourt Onne within an impressive 90-day timeframe. Tasked with ensuring high standards and efficiency, I worked diligently on this significant undertaking. The WACT office was strategically designed to meet the unique needs of the terminal, offering a modern and functional workspace. The project involved the transformation of the office into a dynamic environment, aligning with the professional standards expected in the industry. With a focus on accommodating diverse work styles and fostering collaboration, the office space was organized into various sections,...
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