Tips for hand-mixing epoxy

To achieve optimum
cured properties,
proper proportioning
and mixing are crucial

ather than using a drum Casual mixing isn’t enough. Every par- stored in the field at ambient tempera-

R mixer, workers often mix

small amounts of epoxy
by hand. The process
seems simple, the results
appear acceptable. Many workers,
however, don’t realize that propor-
tioning and mixing greatly affect the
hardened properties of the cured
epoxy. Poor bond often is the result of
poor mixing. Make sure your workers
understand the requirements of mix-
ing epoxy by hand.
Hand-mixing applications
Some applications don’t require
much material. Also, a combination
of short pot life and time-consuming
placement can result in throwing
away hardened epoxy that sets in the
bucket before use. Some applica-
tions, therefore, almost always dic-
tate hand mixing. Workers often mix
epoxy by hand for these common
applications:
• Set anchor bolts, dowels, or pins.
• Fill under base plates.
• Bond fresh concrete to hardened
concrete.
• Anchor ports and seal cracks prior
to pressure injection.
• Repair spalls.
Contractors find many other appli-
cations requiring small amounts of
materials that make hand mixing the
economical choice.
ticle of hardener must connect to a resin
particle.
Epoxy undergoes a setting process
(Figure 1). After the resin is mixed
with the hardener, the material has a
useable pot life, then gels, and finally
hardens into a solid.
A good mix hardens into a solid with
hardener and resin particles intercon-
nected like a chain link fence. Poor mix-
ing results in weak spots where the hard-
ener and resin aren’t firmly connected.
The result: a chain link fence with some
of the links cut (Figure 2). The cut or
incomplete links are weaknesses where
failure can begin. Correct mixing
ensures a complete chain link fence.The
hardened (cured) epoxy has high bond
strength, low shrinkage, and excellent
chemical resistance.
Temperature conditioning
Epoxy components sometimes are
tures below 50°F. Whenever possible,
heat the components before mixing.
Heated ingredients have a lower vis-
cosity, making mixing easier and
faster. Also, a lower viscosity reduces
the tendency to whip air into the fluid
epoxy during mixing.
If the components are above 90°F,
the resulting fluid mix will have a
shortened pot life. In these cases, pre-
cool the materials to extend their pot
life.
To heat components, simply bring
them inside at night or store them in a
heated room. Or immerse the compo-
nents in their containers in a heated
water bath. Likewise, the components
can be cooled in a bath of cold water
or stored in a refrigerator.
If aggregates are used to make
epoxy mortar, they also may need to
be temperature-conditioned. The
aggregate temperature will affect the
mortar’s pot life. A hot aggregate will

The importance of
proper mixing
The chemical reaction that occurs
when an epoxy resin is mixed with a
curing agent changes the liquid to a
solid. To accomplish this reaction
Figure 1. Once mixed, epoxy undergoes a setting process. Many epoxies have short
effectively, the hardener must be dis- pot lives, so small batches must be hand-mixed.
persed thoroughly in the epoxy resin.
reduce pot life and a cold aggregate
will extend pot life. Aggregates
should always be oven-dry.
Check the manufacturer’s recom-
mendations for storage temperatures,
temperature conditioning, and pot life
at temperature extremes.
Proportioning
Some workers alter the specified
mix ratio of the components, thinking
they can get the epoxy to set faster or
slower. Don’t do this! When
improper amounts of the resin and
hardener are blended, the chemical
reaction will be incomplete and the
resulting solid material won’t perform
as expected.
Shoot for a plus-or-minus tolerance
of 2% when proportioning epoxy
components. Do not guess or eyeball
the weights or volumes. The best
method of proportioning is to use the
entire preproportioned containers sup-
plied by the manufacturer. This isn’t
always feasible when hand mixing
small quantities of epoxy. For smaller
portions, get two different colored
cups that match the volume ratio
specified by the manufacturer. Label
one cup “resin” and the other cup
“hardener.” Dip the resin cup into the
resin container filling the cup. Strike
off the excess, then place the contents
of the cup in the mixing container.
Now, take the hardener cup and
repeat the process. The mixing con-
tainer should contain the correct pro-
portions of resin and hardener. Repeat
the process as many times as neces-
sary to obtain the desired amount of
epoxy resin.
Mixing
The resin typically is thicker and
heavier than the hardener, so they
don’t always blend together too eas-
ily. Before blending, mix the compo-
nents separately to reduce their vis-
cosity and make them easier to blend.
After mixing each component for 2
to 3 minutes, place correctly propor-
tioned amounts of each ingredient in
a mixing container. The mixing con-
tainer, usually a 5 gallon bucket, must
be clean and free of dirt, oil, grease,
or other contaminants.
Blend the components with a low-
speed drill (about 400 to 600 rpm)
equipped with a squirrel cage mixing
paddle. Mix for about 11⁄2 minutes,
scrape the sides and bottom of the
bucket, then mix for another 11⁄2 min-
utes. When mixing, move the paddle
in a circular pattern with an up-and-
down motion.
Many compounds have their com-
ponents distinctly pigmented so that
mixing produces a third color. This is
very helpful in determining when a
complete mix has been achieved. Con-
tinue mixing until the epoxy is a uni-
form color with no streaks. This may
take as little as 2 minutes or as long as
10 minutes depending on viscosity,
density, and flow characteristics of the
epoxy.
Thoroughly blend the epoxy before
adding any aggregates. Then slowly
add the aggregate and mix to a uni-
form consistency. Check with the
epoxy manufacturer for aggregate
proportions.
The Don’ts of Hand-mixing Epoxy
DON’T alter the specified resin-
hardener ratio.
Some workers think that changing
the amount of hardener is an acceptable
way of changing the rate of cure. Not
only is this a false assumption, but doing
so can greatly worsen the cured epoxy
properties.
DON’T use a high-speed drill.
A high-speed drill can whip air bub-
bles into the mix. Although the resulting
volume is greater, the epoxy is weaker.
Slow the drill speed if air bubbles appear
in the top surface of the mix.
DON’T use epoxy that’s stuck to
the mixing paddle.
Epoxy can cost $40 to $50 a gallon,
so there’s a temptation to use every last
bit. However, the epoxy stuck to the
mixing paddle isn’t thoroughly mixed.
Also, be very careful about using the
epoxy stuck to the bottom or sides of the
container.
DON’T use epoxy that contains
spots or streaks after mixing.
Unfortunately, a uniform color isn’t
always a sure sign of uniform consis-
tency. It’s better to overmix than it is to
undermix. Some workers see a small
PUBLICATION #R940011
Copyright © 1994, The Aberdeen Group, All rights reserved
Figure 2. Proper mixing of epoxy results
in a cured material resembling a chain-
link fence. Inadequate mixing results in
a fence with some of the links cut. The
cut or incomplete links are weaknesses
where failure can begin.
spot of a different color, then fold the
material over it. This doesn’t blend the
material, it only hides it. If the epoxy
contains streaks or spots, continue mix-
ing for another minute.
DON’T mix epoxy in a bucket con-
taining partially cured epoxy.
Repeating batches in the same con-
tainer is fine, as long as the previously
mixed epoxy is still fresh or completely
hardened. Completely hardened epoxy
flakes off, becoming an adequate filler
material. However, if the epoxy is only
partially cured, it can flake off into the
fresh batch creating a local weak bond.
Also, do not use a bucket containing
dirt, oil, or grease.
DON’T forget to follow the manu-
facturer’s recommendations for safe
mixing, which typically include:
• Avoiding eye and skin contact.
• Removing contaminated clothing and
shoes.
• Providing adequate ventilation to
avoid breathing vapors.
• Wearing a NIOSHA/MSH organic
vapor respirator.
• Using safety goggles and chemical-
resistant gloves.