abeco mastic

Heavy duty mastic flooring system

DESCRIPTION PHYSICAL AND CHEMICAL

PROPERTIES PREPARATION OF SUB-FLOOR
abeco mastic is a cold-laid bituminous Recommended laid
mastic consisting of stone chippings, 12 mm
thickness The sub-floor should be clean and free
Portland Cement, sand and a binder, 2
±24 kg/m at from dust, dirt, loose material, oil,
flintkote 3. Mass of laid mastic grease and other foreign matter.
12 mm
Indentation A load of 2 MPa Grease and oil should be removed by
USES resistance should not indent washing with detergent. The surface
the surface more must then be well washed with water
abeco mastic has been successfully than 0,5mm at and allowed to dry. Sub-floors must
used in numerous flooring applications 12 mm thickness always be surface dry.
and has more than 45 years of service at 20ºC
history on the South African market. K factor – 0,8 Surface preparation:
Single areas laid have often exceeded Thermal conductivity 2 The substrate must be dry before
Kcal/m /h/º C
10 000 m². Joints are normally Approx. 1,3 x application
unnecessary. Construction joints Volume electrical 11 Electronic moisture content tests must
10 ohm-cm at
disappear after a few days of traffic resistivity be conducted prior to application of the
12 mm
exposure. ±1 260 volts/mm priming system. Maximum moisture 4-
Also for floor repair, including timber. at 12 mm 5% max. (eg Protimeter Survey Master
surfaces Dielectric strength or equivalent)
thickness at 60
Installations include: cycles/sec. or
warehouses, railway platforms, printing Service temp limits -10º C to 80º C Dynamic Calcium Chloride moisture
works, grocery warehouses, explosive “weight gain” over 24 hours
Application temp
magazines, heavily trafficked corridors, 5º C to 40º C or
range
textile factories, goods sheds, loading (a practical overnight “plastic sheet
Non-flammable,
bays, paper storage and packing Fire resistance test” is also advisable approx. 1m²
wet or dry
areas, cold rooms, carpentry masked down on surface)
workshops, flour mills, ships decks. Drying time to
36 to 48 hours
trafficability
BONDING / PRIMING
abeco mastic should not be used Drying time to initial
1 – 6 hours
where it will be exposed to mineral or set
The priming solution is made by
vegetable oil, mineral or fatty acids, Resistant to water diluting flintkote 3. Stir well during and
solvents, continuous wet or abrasive spillage and after the addition of water.
conditions, point loading, such as 200 washing, alcohol, Apply a brush coat of this material to
litre drums rolled on edge. most salt the clean, dust-free sub-floor at the
Chemical resistance solutions, dilute
rate of 2 m²/l.
FEATURES & BENEFITS alkalis. Not
This coat, which goes on as a dark
resistant to oil,
brown paint, rapidly dries to a black
ƒ Produces a jointless, non-dusting, grease, fat,
film.
warm, resilient, quiet floor surface solvents, acids
If the dry film does not completely
which is non-slip, verminproof, Kerosene or white blacken the sub-floor surface, apply a
Clean-up after laying
dampproof, non-flammable and self- spirits
second coat immediately. If the sub-
healing under traffic including the Store above 0º C floor is not fully sealed after two coats
Storage of binder
heaviest loads carried on steel, under cover of primer, a third and even a fourth
plastic or rubber-wheeled vehicles. Shelf life 12 months may be used. Allow to dry fully before
ƒ Does not produce disintegration – Surface temp. proceeding further.
Suitability for
may be laid over any firm, sound, must not exceed
underfloor heating
clean sub-flooring including 32º C. BOND COAT
concrete, asphalt, well-compacted System dries to a Immediately before the mastic layer is
Colour
crusher run, steel and timber. black finish placed, apply an undiluted coat of
ƒ Laid to a nominal 12 mm dry flintkote 3 brushed on at the rate of
thickness abeco mastic dries to a 0,75 liter / m².
dark brown colour. The mastic MUST be laid into the still
wet bond coat.
Revision 9203

Karachi: Room No.1, Mezzanine Floor, Al-Hayat Chambers, A-7, Block-7/8, K.C.H.S. Tel: +92 21 4535898-99, Fax: +92 21 4558071
Lahore: 25-A, FCC, Syed Maratib Ali Road, Gulberg 4, Tel: +92 42 5763360 Fax: +92 42 5875384

COVERAGE
flintkote 3, binder: use:-
2
4,13 liters/m for 12 mm thick abeco
stone mastic.
2
2,65 liters/ m for 7 mm thick abeco
sand mastic.
MIXING
Mixing is normally done by hand using
shovels. Ideally there should be at
least two operators per mix.
Mechanical pan mixers with revolving
drums and rotating paddles may also
be used.
Conventional drum concrete mixers
are not suitable.
Mix sizes should be such that the
entire quantity prepared can be laid
within 30 minutes.
Laying delayed beyond the time when
the emulsion has started to break, will
cause rapid failure in service.
The sequence of mixing is:
• Thoroughly blend the stones, sand
and cement.
• Add sufficient water to just dampen
the material. About 25% by volume
is generally sufficient if the
aggregate is air dry, less than this if
the aggregate is wet from rain,
washing or other moisture.
• Add the total amount of flintkote 3
to the damp aggregate. Ensure that
any lumps that form are completely
broken down during mixing.
• Extra water may be added to adjust
workability of the mix. The
consistency must be such that the
vertical face resulting from a shovel
cut into the mix, is just short of
flowing.
Prolonged mixing must be avoided as
this can cause the binder to shear – a
defect not obvious in the wet mix but
which leads to rapid failure in service.
LAYING PROCEDURE
With the bond coat still wet, dump the
mix onto the prepared area and, using
a wood float or rake, spread the mix
between screed rails to a level slightly
higher than the screed rails.
Consolidate by tamping and then strike
off to the correct thickness, using a
straight edge laid across the screed
rails and worked to and fro with a saw
like motion whilst progressing forward.
Close and smooth the surface with a
wooden float which should be kept
Karachi: Room No.1, Mezzanine Floor, Al-Hayat Chambers, A-7, Block-7/8, K.C.H.S. Tel: +92 21 4535898-99, Fax: +92 21 4558071
Lahore: 25-A, FCC, Syed Maratib Ali Road, Gulberg 4, Tel: +92 42 5763360 Fax: +92 42 5875384
damp and free of semi-dry and dry
material.
A finer finish may be obtained by
following up with steel trowelling just
before the mastic achieves its initial
set. The time for this will depend upon
the drying rate of the job in hand and
can only be determined by inspection.
If steel trowelling is excessive or
carried out too early, a large proportion
of fines may be worked to the surface
resulting in a weak surface layer.
On large areas, it is usual to lay mastic
in alternate bays, the laid and cured
panels acting as a depth gauge for the
subsequent adjoining areas. To
compensate for the shrinkage that will
occur as the new placing dries, a strip
of 3-ply malthoid must be put down
on the set material to increase its
thickness before using it as a screed
rail for the new material.
SPECIALIST SUB-
CONTRACTING FACILITIES
abe will be pleased to advise
prospective abeco mastic users of the
names of specialist sub-contractors
operating in specific geographical
areas.
abeco mastic AS A FLOOR
REPAIR
abeco mastic makes an excellent
repair material for potholed, damaged
or ravelled concrete floors.
Patching carried out on a Saturday
morning, is normally available for full
operation on Monday morning with no
danger of the patch pulling out.
Patching Procedure
The area involved must be freed of all
dust, loose material and cracked
aggregate. Oily and greasy
contamination must be removed
completely.
Edges should be squared although this
is not obligatory.
Surfaces to be treated must be primed
as previously described with the
priming coats extending onto sound
concrete by approximately
75 mm.
Immediately before patching is placed,
a bond coat must be applied. The
damaged area is then filled with mastic
to some 5 mm above final level,
carrying the mastic onto the primed
surround with a feather edge. The
mastic must be well compacted with a
wooden float. Any shrinkage
developing during drying, will close
under traffic.
Where damaged areas are of the order
of 20 - 30 mm deep, mastic should be
applied in two layers. The first layer
should fill the hole to within 12 mm of
final surface and be allowed to dry.
The final levelling then proceeds as
described. The dried filling must
receive a bond coat.
Where potholes are in excess of
30 mm deep, they should be cleaned
out and patched with concrete to within
12 mm of final surface. As soon as
concrete has set, the patching to final
level with abeco mastic proceeds as
already outlined.
Where patching is shallow (below
12 mm), aggregate size should not
exceed 3 mm size and where the
thickness is less than 6 mm, abeco
sand mastic should be used.
Repairing V-joints in concrete floors
V-joints in concrete floors often
present hazards to small-wheeled
traffic. These joints can be filled very
easily with either stone or sand mastic
using the details given in this data
sheet.
Prime and bond the surface as usual.
Fill in the joint with a slight excess of
mastic to allow for shrinkage and
bedding under traffic.
The choice of whether stone or sand
mastic is used, will depend upon joint
sizes.
Repairing timber floors
abeco mastic can be used on timber
floors with the same modifications to
the foregoing systems.
• The timber must be clean and free of
wax.
• Ensure that all floor boards are firmly
nailed to their supports.
• Staple 12 mm chicken wire mesh to
the boards and use this as a
reinforcing for the mastic.
• Lay the mastic 15 – 20 mm thick
PROTECTION ON COMPLETION
Protect the surface against traffic and
spillage until cured. See 'Laying
Procedure' regarding shrinkage.
CLEANING abeco mastic
FLOORS
abeco mastic floors can normally be
kept clean by washing down with
detergent and water. They may also
be waxed using an emulsion based
floor wax.
Revision 9203
 direct or continuous control over where
TEMPERATURE AND RELATIVE and how abe products are applied -
HUMIDITY accept any liability either directly or
indirectly arising from the use of abe
See Physical and Chemical Properties products, whether or not in accordance
table. with any advice, specification,
recommendation, or information given
MODEL SPECIFICATION by the company.
FURTHER INFORMATION
Heavy-duty mastic flooring system.
Where other products are to be used
The flooring will be abeco mastic, a in conjunction with this material, the
heavy-duty mastic flooring system relevant technical data sheets should
combining flintkote 3 bitumen be consulted to determine total
emulsion mastic binder with selected requirements. abe Construction
aggregates and cement applied in Chemicals has a wealth of technical
accordance with abe Construction and practical experience built up over
Chemicals' recommendations. years in the company’s pursuit of
excellence in building and construction
PACKAGING technology.

The binder, flintkote 3, is supplied in

5 l, 25 l and 200 l.

HANDLING & STORAGE

All abeco mastic related products

have a shelf life of 12 months if kept in
a dry, cool store in the original,
unopened packs.
If stored at high temperatures and/or
high humidity conditions, the shelf life
may be reduced.

HEALTH & SAFETY

Wet abeco mastic is mildly toxic and

non-flammable. Always ventilate the
working area well during application
and drying. Avoid inhalation of dust
and contact with skin and eyes.
Suitable protective clothing, gloves,
eye protection and respiratory
protective equipment should be worn.
The use of barrier creams provides
additional skin protection. If contact
with skin occurs, wash with water and
soap. Splashes into eyes should be
washed immediately with plenty of
clean water and medical advice
sought.

Cured abeco mastic is inert and

harmless

IMPORTANT NOTE

This data sheet is issued as a guide to

the use of the product(s) concerned.
Whilst abe Construction Chemicals
endeavours to ensure that any advice,
recommendation, specification or
information is accurate and correct, the
company cannot - because abe has no

Revision 9203

Karachi: Room No.1, Mezzanine Floor, Al-Hayat Chambers, A-7, Block-7/8, K.C.H.S. Tel: +92 21 4535898-99, Fax: +92 21 4558071
Lahore: 25-A, FCC, Syed Maratib Ali Road, Gulberg 4, Tel: +92 42 5763360 Fax: +92 42 5875384
SHRINKAGE CRACKING AND CURING

It is common for abeco mastic to exhibit shrinkage cracking on overnight drying. Unlike shrinkage cracking of concrete screeds, THIS IS
NOT IMPORTANT. A few days of wheeled traffic will seal the cracks completely.
Shrinkage cracking is normally due to too rapid drying of mastic and may be caused by several factors such as Insufficient sealing of the
sub-floor, draughts, sunlight, hot atmosphere.
To retard cure, the trowelled surface can be covered with polythene sheets for a few hours.
However, if cracks are very wide or some other reason dictates action, the following system may be used for sealing them:
MATERIALS • CRUSHER DUST screened through fly screen 4 volumes
(14 – 16 mesh) and retained material discarded
• PORTLAND CEMENT 0,25 volume
• flintkote 3 1 volume
• WATER 3 volumes
MIXING • Blend crusher dust and cement and dampen with water.
• Mix in Flintkote 3.
• Add rest of water and mix thoroughly.
METHOD OF USE Pour the resultant sloppy slurry into the cracks and strike off with edge of a steel float.
Never use a gauge larger than 1 litre even if a considerable amount of patching has to be done.

Approximate Mix Proportions for abeco

Materials Loose bulk density Relative density
Stone (5 mm) 1 300 kg/m³ 2,70
Sand 1 100 kg/m³ 2,60
Cement 1 667 kg/m³ 3,14
Abeco 1 000 kg/m³ 1,00
Water 1 000 kg/m 1,00
Volume conversions 1 000 litres/m³ or 1 litre provides 1 m²/mm thickness

Stone mastic used for plus 7 mm thickness (thickness should double stone size)
Materials Volumetric mix Mass – kg Absolute volume
Stone (5 mm) 120 156 57,78
Sand 60 66 25,38
Cement 30 50 15,92
Flintkote 60 60 60,00
Water for dry sand 15 15 15,00
Total 347 174,09
Approximate coverage 14,5 m² for above ratios @ 12 mm thickness

Sand mastic used for 7 mm or less thickness

Materials Volumetric mix Mass – kg Absolute volume - Yield
Sand 105,45 116 44,62
Cement 30 50 15,92
Flintkote 3 45 45 45
Water for dry sand 15 15 15
Total 226 120,54
Approximate coverage 17 m² for above ratios @ 7 mm thickness
Priming: Allow 1 litre/ m² using Flintkote 3 (subject to surface porosity)

Note:
Adjust the water content for the moisture in the aggregates (i.e. less water for moist aggregates),
All quantities must be measured accurately, Clean 5 litre or 25 litre containers make excellent gauges,
Methods such as barrows or shovels must NEVER be permitted.

Recommended Sand Grading Recommended Stone Grading

Sieve Size (mm) Cumulative % Passing Sieve Size (mm) Cumulative % Passing
4.750 100 - -
2.360 85-95 - -
1.180 70-80 19.000 100.0
0.600 45-55 13.200 100.0
0.300 10-20 9.500 95-100
0.150 2-10 6.700 70-90
0.075 0 4.750 0-10
Revision 9203

Karachi: Room No.1, Mezzanine Floor, Al-Hayat Chambers, A-7, Block-7/8, K.C.H.S. Tel: +92 21 4535898-99, Fax: +92 21 4558071
Lahore: 25-A, FCC, Syed Maratib Ali Road, Gulberg 4, Tel: +92 42 5763360 Fax: +92 42 5875384
 Revision 9203

Karachi: Room No.1, Mezzanine Floor, Al-Hayat Chambers, A-7, Block-7/8, K.C.H.S. Tel: +92 21 4535898-99, Fax: +92 21 4558071
Lahore: 25-A, FCC, Syed Maratib Ali Road, Gulberg 4, Tel: +92 42 5763360 Fax: +92 42 5875384