Method statement

constructive solutions

Nitowrap FRC Carbon Fibre Sheet

Installation Procedure
Contents
1. Surface Preparation Grinding
2. Surface Repair
3. Primer Application
4. Filling of Surface Irregularities with Epoxy Putty
5. Application one coat of Encapsulation Resin
6. Application of Carbon Fibre Sheet
7. Curing
8. Finish Coating with Encapsulation Resin

Fosam Company Limited

Head Office
Post Box 11081
Jeddah 21453
Saudi Arabia

www.fosroc.com

Telephone: +966 2 637 5345

Fax: +966 2 637 5891

email: fosam@fosroc.com

Regional Offices
Jeddah Sales Office
Jeddah Showroom
Riyadh
Dammam
Khamis Mushayt

Tel: (02) 6080999

Tel: (02) 665 0787
Tel: (01) 482 9303
Tel: (03) 814 1282
Tel: (07) 250 0469

Fax: (02) 635 3330

Fax: (02) 667 4884
Fax: (01) 482 7562
Fax: (03) 814 1581
Fax: (07) 250 0469

Yanbu Tel: (04) 322 4280

Makkah Tel: (02) 542 0869
Medinah Tel: (04) 845 1767
Jubail Tel: (03) 362 3904

Registered Office: Industrial Area, Phase 4, Road No. 414, Street No. 407

Fax: (04) 391 2980

Fax: (02) 542 0869
Fax: (04) 846 3195
Fax: (03) 362 3875

Method statement

constructive solutions

Standard Installation Flow

Surface Preparation Grinding

Surface Repair

Primer Application

Filling of Surface Irregularities

With Epoxy Putty

Application of Encapsulation Resin Coating

Application of Carbon Fibre Sheet

Curing

Finish Coating

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Method statement

constructive solutions

Surface Preparation Grinding

Objective
To provide a strong concrete surface that will allow maximum adhesion for carbon sheet and resin
application.
To eliminate through grinding, any convex sharp corners in preparing for the application of carbon sheet.
Procedure
Remove the deteriorated surface of the concrete (weathering, laitance, oil, paint, coatings, chipped mortar
and other surface contaminants) using a hand grinder until a hard surface is obtained.
After grinding, the desired surface condition is a hard and smooth surface. During carbon sheet application,
there should be less than 1mm in surface differentiation.
When encountering an area where a sharp corner occurs, the corner must be ground down to a
radius in excess of 10mm. And in the case of application of high modulus carbon sheet (FRC-H300)
the ground radius must exceed 20mm. This is to allow a smooth uninterrupted surface in the
application of the carbon sheet.

R = 10mm

Concrete
After grinding, all dust and contaminants should be removed using compressed air or vacuum and wiping
with clean cloth. If water is used in cleaning, insure that the surface is completely dry before proceeding to
application steps.

Equipment and Tools

Disc Grinder
Compressor or Vacuum, Cleaning cloths
Hard Hat, Safety Glasses, Filter Mask, Gloves and assorted safety wear.
Remarks
Surface repair and preparation is the most important step in the entire application process.
To reduce necessary work in the final surface step, it is important to achieve as smooth a surface as
possible during the initial surface preparation grinding step.
Wear protective helmet, safety glasses and filter mask to prevent injury from flying debris and dust.

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Method statement

constructive solutions

Surface Repair
Objective
To repair any damage to the concrete surface and remove any major surface differentiation.
To fill any large concave indentations to provide a smooth, level concrete surface.
Procedure
1. Fill any holes or irregularities in the concrete surface using mortar that is equal to or higher in
strength to the concrete substrate.

Concrete

Nitomortar FC
2. Weather and rustproof any protruding steel or metal surfaces.
3. Fill any cracks in the surface with an epoxy based resin.
4. The repaired surface should not have any surface differentiation in excess of 1mm.
Equipment and Tools
All supplies needed for surface repair (concrete mortar, epoxy resin, rustproof coating etc.).
Remarks
After the grinding and surface preparation steps, a thorough inspection of the surface must be made to insure
complete repair and surface preparation. This is done to avoid repeating these steps again at a later stage in
the installation process.
As in the previous surface preparation procedure, the repaired surface must be smooth and void of
irregularities and surface differentiation in excess of 1mm.

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Method statement

constructive solutions

Primer Application
Objective
To strengthen the concrete surface for application.
To fill all small holes and voids in the concrete surface prior to application.
To provide a chemically compatible surface for maximum resin adhesion.
Procedure
1. Before starting the mixing of primer prior to application, the area, resin type, and manpower to be used must
be calculated in order to complete the primer application prior to exceeding the pot life of the primer during
the application process.
2. Mix the primer using an electric hand mixer to a resin / hardener ratio of 2:1 for a period of approximately two
(2) minutes.
3. Apply the primer uniformly over the prepared surface using an application roller.
4. Areas that have excessively absorbed the first coat of primer, must have a second coat applied to that area,
after complete drying of the first coat (usually the next day), in order to insure a uniformly coated surface.
Equipment and Tools
For Mixing Primer : Mixing Container (Round Shaped), Electric Hand Mixer, Mixing Scale.
For Primer Application : Application Roller, Application Roller Pan.
Safety Glasses, Rubber Gloves, other safety wear and equipment as required.
Thermometer and Hygrometer
Remarks
Primer must not be applied in an environment that is less than 5C or in excess of 85% RH.
Primer must be mixed in a round mixing container and both mixing container and roller pans should be of the
disposable type and used only once or cleaned completely with Acetone after each use.
Primer must be disposed of immediately if application time exceeds pot life.
Mixed primer volume and environmental temperature determine pot life (Larger volumes or higher
temperatures tend to reduce the pot life of the primer) therefore, pot life can vary with differing factors.
After the primer is mixed, if the temperature or viscosity rises the pot life has been exceeded and application
should stop immediately.
During primer application, avoid using Fibre-based gloves to prevent contamination of the primer or surface

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Method statement

constructive solutions

Filling of Surface Irregularities with Epoxy Putty

Objective
To provide a final surface free of irregularities prior to carbon sheet application.
Procedure
1. Fill any remaining holes or surface irregularities with epoxy putty to obtain a surface that is smooth.

Nitomortar FC

2. When encountering an area where a concave sharp corner occurs, the corner must be filled with
epoxy putty to a radius in excess of 10mm. And in the case of application of high modulus carbon
sheet (FRC-H300) the filled radius must exceed 20mm. This is to allow a smooth uninterrupted
surface in the application of the carbon sheet.

Concrete
R 10mm

Nitomortar FC

3. Inspect all surfaces to insure that there are no surface irregularities or differentials in excess of 1mm.
Equipment and Tools
Mixing Plate for Epoxy Putty
Rubber, Plastic and Steel Putty Scraper
Putty Knife
Safety Glasses, Rubber Gloves, other safety wear and equipment as required.
Thermometer and Hygrometer.

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Method statement

constructive solutions

Remarks
After the primer is dried, a thorough inspection of the surface must be made to determine areas that will
require application of epoxy putty.
Epoxy Putty must not be applied in an environment that is less than 5

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or in excess of 85% RH.

Method statement

constructive solutions

Application of Carbon Fibre Sheet

Procedure
4. Prior to the actual application of the carbon sheet, a plan must be calculated taking into account the size and
shape of the prepared surface, application environment, resin type and pot life and the available manpower
for application.
5. The carbon sheet should be cut into the appropriate lengths according to the installation plan, using scissors
or a cutter in advance of the installation.
6. The proper volume of resin must be mixed in order to avoid exceeding pot life of the resin during application.
7. Using a hand electric mixer, mix the resin and hardener at a ratio of 2:1 for a period of approximately 2 3
minutes depending on the volume being mixed.
8. Immediately after mixing, apply the undercoat of resin to the prepared surface using an Application Roller.
- FRC-N200 Sheet
: Undercoat coverage should be 400 500 g/m2
- FRC-N300, H300 Sheet : Undercoat coverage should be 500 g/m2
9. Immediately after applying resin to the work area, the pre-cut carbon sheet should be applied to the same
area using a rubber or plastic scraper. After application of the sheet the release paper backing should be
removed and discarded properly.
10. In order to gain the proper impregnation of the carbon sheet, the sheet should be rolled using an
impregnation roller in a direction parallel to the Fibres in the carbon sheet.
11. After waiting a minimum of 30 minutes, and within 3 hours, after the impregnation of the undercoat of resin,
the topcoat of resin should be applied in the same manner to the carbon sheet using the Resin Application
Roller. Then the topcoat of resin should be smoothed out utilizing a rubber or plastic scraper.
- FRC-N200 Sheet
: Topcoat coverage should be 100 200 g/m2
- FRC-N300, H300 Sheet : Topcoat coverage should be 150 g/m2
12. In the case of two (2) ply applications the application of the second (2nd) ply should not be initiated until the
first (1st) ply has reasonably hardened (usually next day). Then follow the same procedure as the above
steps, undercoat, carbon sheet, impregnation, topcoat.
Equipment and Tools
For planning and cutting of sheet : Measuring tape, ruler, heavy-duty scissors, and cutter knife
For resin mixing : Mixing container (round shape), electric hand mixer, mixing scale.
For Resin and Sheet application: Application Roller, Roller Pan, Impregnation Roller, Plastic or Rubber
Scraper.
Safety Glasses, Rubber Gloves, other safety wear and equipment as required.
Thermometer and Hygrometer.

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Method statement

constructive solutions

Remarks
Cautionary remarks for Resin Application are the same as those for Primer Application
All steps (including impregnation rolling) must be completed within the pot life time of the resin being applied.
To increase the efficiency of application, it is recommended that the carbon sheet to be applied, as well as all
tools and equipment to be used, be prepared in advance of the mixing of the resin.
Caution should be taken in sheet handling to insure that the Fibres are not bent or broken on their
longitudinal axis. (Do not fold or roll up the sheet tightly)
When applying the carbon Fibre sheets, they should overlap (in excess of 10cm) on top and bottom edges
(longitudinally). An overlap is not required on the sides.
During impregnation of the undercoat of resin, the sheet should be rolled continuously.
In case of application of multiple plies, the proper procedure is to apply only one (1) ply per day. The
previous ply must dry completely and be inspected for any air pockets, bubbles or areas of non-adhesion and
repaired.
Repair procedure for air pockets, bubbles and areas of non-adhesion.
- Small Areas : Cut the affected area on the longitudinal axis and apply resin generously to the area until
properly adhered.

Large Areas : Cut and remove the affected area and re-apply an overlapping section to cover the

exposed area (overlap must exceed 10cm).

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Method statement

constructive solutions

Finish Coating
Procedure
1. After completing the application of the carbon sheet, apply the proper finish coating to the completely cured
surface.
2. Complete cure times for resin application is 7 days @ 30 C.
3. Application procedures are different depending on the type of finish coating to be applied. Please consult the
application instructions of the finish coating manufacturer.
4. In external applications, the finished area should be covered with a weatherproof cover to prevent exposure
to rain and moisture and other contaminants prior to finish coating application.

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