ELIMINATOR® Trafficable Ballast Layer Application Guidelines

Contents

1. Introduction
2. Surface Preparation
3. Treatment of Joints
4. Application of Trafficable Ballast Layer
5. Hand Application
6. Pump Application
7. Application to Verticals
8. Application to the Horizontal Deck
9. Day Joints
10. Repairs
11. Quality Control
12. Cleaning of Tools and Equipment
13. Health & Safety
14. Packaging & Storage

_{Appendices
Appendix: Cure Ladder}

1. Introduction

1. This document must be read in its entirety prior to commencing application.
2. It is recommended that these Application Guidelines are read in conjunction with the relevant product datasheets.
3. Only Contractors trained by GCP are authorized to apply the Trafficable Ballast Layer (TBL).

2. Surface Preparation

1. The ELIMINATOR® membrane must be inspected to ensure the surface is dry, clean and free from loose debris, moisture and other contaminants before the Trafficable Ballast Layer is applied.
2. Any oil, grease, diesel, gasoline, or contaminants must be removed using a cloth soaked in Acetone. Do not pour the Acetone onto the membrane.
3. The use of tri-burners, thermal lances etc. must be avoided when drying the ELIMINATOR® membrane.
4. If there is a risk of contamination from other trades during work operations, adequate protection to prevent this should be provided. The ELIMINATOR® membrane must be inspected and approved by the Authorized Contractor and Engineer prior to the start of application of the TBL to ensure the prepared substrate meets the required standards.
5. For treatment of other substrates contact GCP Technical Services for guidance.

3. Treatment of Joints

1. Detailing of joints should be treated in accordance with the site-specific specification and must be agreed in advance with GCP, the Authorized Contractor and the Owner Representative.

4. Application of Trafficable Ballast Layer

The Trafficable Ballast Layer consists of: Resin supplied in pails and a box of BPO powder or resin supplied in drums and a pail of liquid BPO.

All components of the system must be premixed prior to use. The contents of the pail/drum shall be stirred thoroughly/pre-mixed immediately prior to use, using a mechanical stirrer, such as an air-driven drill (400-800rpm) and mixing paddle. Some settlement may occur during storage and transportation so stirring should continue until the mix is fully homogenized. Scrape round the sides and base of the container to ensure thorough mixing. It is recommended that a dedicated mixing paddle for use with heavily filled mortars be used. In our experience the best mixer for this application is the Makita Mortar mixing paddle from Screwfix Direct Item No.98121 or similar.

To assist quality control, coverage rate and wet film thickness (WFT) shall be monitored to ensure proper application to the specified thicknesses. In addition, total material applied against the total area covered must be recorded daily on the Site Q.A & Materials Record.

Surface drying of the membrane is best achieved using an air lance fitted with an oil/water filter.

The Authorized Contractor must use masking tape or other approved means to provide a neat finish and prevent contamination of adjacent sections.

The Trafficable Ballast Layer should be applied to the verticals in a separate action, prior to applying it to the horizontals. All verticals shall be cut in according to a survey of existing as-built site conditions.

Application methods (hand/pump) should be considered due to site conditions prior to start of work operations.

5. Hand Application Method: For Applications using pails and powder BPO

1. After premixing the components, add the correct amount of BPO and mix thoroughly until it has all dispersed. Scrape around the sides and base of the container to ensure thorough mixing. Once the BPO is added it initiates the 'working life' of the material during which time it should be applied. The 'working life' of the material will vary depending upon the quantity mixed, the substrate, ambient and material temperature and the level of BPO addition. Refer to Appendix 5 for further information on working life and cure times. Mix only enough material that can be applied within the working life.

6. Pump Application: For Applications using drums and liquid BPO

For direction on proper use of the Trafficable Ballast Layer Pump refer to the appropriate Operation Manual.

Pump the Trafficable Ballast Layer material onto the membrane and spread it out evenly over the surface appropriately sized equipment to achieve the specified thickness and finish.

For applications that call for a project specific profile (e.g. to promote drainage), application equipment of commensurate size and shape shall be used that will allow the material to cure to an appropriate finish and thickness compliant with the project submittals. Contact GCP for further guidance and Technical Advice Note.

All application equipment must be cleaned regularly to prevent build-up of cured material.

Remove all masking before the Trafficable Ballast Layer starts to gel. If the Trafficable Ballast Layer has started to gel the utmost care must be taken when removing the tape to avoid disturbing it as it could affect its adhesion to the membrane.

Once applied the Trafficable Ballast Layer must be allowed to fully cure before trafficking. Refer to the Appendix for further information on working life and cure times. To prevent unnecessary contamination, it should be protected from other trades until such time the area is ready to be opened.

7. Application to Verticals

If called for in the project specifications, apply TBL to all vertical substrates first in one coat application, at a minimum coverage rate of 20 ft²/gal (80 mils) which may increase with surface irregularity. The material shall extend out onto the deck horizontally by 3” minimum.

The top edge of the TBL should be measured out using a chalk line with masking tape positioned accurately to create a neat finish. The Trafficable Ballast Layer should be applied to a minimum of 6” up the vertical, unless otherwise directed by the Owner. The vertical edge should be measured and masked in a straight line. Where it is not possible to carry up a vertical 6”, agreement should be reached with the Engineer as to an acceptable height.

Once the Trafficable Ballast Layer has been applied up a vertical remove all the masking/edge tape before it starts to gel.

8. Application to the Horizontal Deck

Generally, application of the Trafficable Ballast Layer shall take place via spray/pump or by using a cam rake, gauge rake, a notched squeegee, screed bar with guiderails or any equipment that will produce a finish that complies with the profile approved in the project documents.

It is recommended to conduct a mock up on-site to verify that the means and methods proposed produce the required finish at the specified thickness in a neat and methodical manner.

Application shall be in one coat at a minimum coverage rate of 20 ft²/gal (80 mils) which may increase with surface irregularity. Single coat applications may be applied at various thicknesses.

Once the Trafficable Ballast Layer has cured, it should be inspected for potential surface irregularities from application equipment. These localized areas should be overcoated as needed to provide a uniform finish.

9. Day Joints

p> No preparation is necessary unless the existing membrane is contaminated on the lap edge, in which case the lap edge must be cleaned with a cloth soaked in Acetone.

No preparation is necessary unless the existing Trafficable Ballast Layer is dirty or contaminated on the lap edge, in which case the lap edge must be cleaned with a cloth soaked in Acetone.

Where new Trafficable Ballast Layer is to be joined to existing cured Trafficable Ballast Layer at a day joint, the new application should be butt joined to the existing material. Care should be taken to ensure all joints are straight.

10. Repairs

1. If the system, or any part of it, has been damaged then you should cut back the damaged area to sound material, using straight cuts to provide uniform rectangular or square shapes. If the system has been damaged through to the substrate, then the substrate will require cleaning. All substrates should be mechanically cleaned. For small, localized areas on concrete substrates this can be achieved with a scrabbling machine or needle-gun. All surface contaminants should be removed completely.
2. If the area around the damaged spot is dirty or contaminated, wipe the periphery of the repair area to 6” using a cloth soaked in Acetone.
3. Mask the area to be repaired ensuring that there is an overlap onto the existing membrane. This also ensures a neat finish.
4. Re-prime the substrate, if exposed, and allow the primer to cure.
5. The repair can be carried out using pre-mixed membrane. Take an equal amount of Part A resin and catalyzed Part B resin and mix together in a small container.
6. Apply the membrane by pouring it onto the repair area and spread it out with a brush or trowel. Spread out the material rather than brushing it out. The membrane must be applied to give a measured wet film thickness equal to original specified application. This should be checked using a gauge pin or standard comb type WFT gauge.
7. Before the membrane starts to gel remove all masking tape. Allow to cure and then reapply masking tape to the damaged area. Apply one coat of Trafficable Ballast Layer in accordance with this document. Allow to fully cure before trafficking.

11. Quality Control

1. The Authorized Contractor must complete a Site Q.C. & Materials Record for each day when any element of the system is applied. A copy must be retained by the Authorized Contractor for record keeping purposes.

12. Cleaning of Tools and Equipment

All tools and equipment should be cleaned using Acetone. Do not allow material to cure on tools as it then becomes very difficult to remove. Flush through all spray equipment with Acetone whenever spraying stops for more than a few minutes.

Do not allow solvent to contaminate the Trafficable Ballast Layer during application as this may result in color variation. All brushes and rollers must be free from solvent before use.

The filters on the spray pump should be checked and cleaned every day.

During the summer months material should not be left in the feed pumps overnight, as at elevated temperatures there is a danger of it curing in the pump.

Keep you spray equipment clean and tidy. Wipe up all splashes and spills as they occur. Conduct a daily operation, cleaning, and maintenance routine.

13. Health & Safety

Safety data sheets for all components of the Trafficable Ballast Layer system and any associated products must be available on site.

The Authorized Contractor must read and understand them before commencing work. Should there be any questions, contact GCP for guidance.

All relevant Health & Safety signage must be posted in advance of any system application to inform members of the public or other contractors, of the application being undertaken i.e. No Smoking, Odor Warning etc.

14. Packaging & Storage

1. All components of the Trafficable Ballast Layer system should be stored in cool, dry, protected conditions, out of direct sunlight and in accordance with the relevant Health & Safety regulations. Storage temperature must not exceed 77°F (25ºC). Do not store any component near open flames or foodstuffs.
2. Stored in unopened containers, under the correct conditions, TBL has a minimum shelf life of 12 months. Please contact us for further details/advice.

APPENDIX: Cure Ladder

Trafficable Ballast Layer Application Temperature Range¹ 23 to 120°F

Maximizing Working Life of the ELIMINATOR® TBL System

To ensure optimal performance and extended working time, follow these best practices:

• Control Resin Temperature: Maintain resin temperature below 95°F. Cooler resin extends working time significantly. For example, reducing the resin temperature from 95°F to 77°F can nearly double the working life.
• Prompt Pouring Post-Mix: Immediately pour the mixed product from the pail after adding the powder catalyst. Delays can accelerate curing due to heat buildup in mass.
• Monitor Substrate Conditions: Asphalt surfaces exposed to direct sunlight can reach temperatures of 145–155°F.
• Aggregate Application: If a dry aggregate over scatter is specified, apply it before the material begins to gel. Recommended coverage is 1.0–1.25 per square foot.

Important Notes:

• As the material approaches the end of its working life, it will stiffen, increase in temperature, and begin to gel. Do not attempt to install or manipulate the product at this stage.
• When using Perkadox 33 as the catalyst, increase the inclusion rate by 25–33% to maintain expected working and cure times.