Wall Brace System

Fiberlock™ is a dry, unidirectional or bi-directional, non-corrosive carbon fiber fabric constructed with high strength carbon fibers. Fiberlock™ fabrics, in conjunction with Fiberlock™ saturates are used to reinforce or retrofit concrete and unreinforced masonry structures. Fiberlock™ Wall Brace Carbon Fiber Fabrics are available in a 12 inch wide unidirectional construction and a 5.5 inch wide bi-directional construction.

KIT CONTENTS

• Carbon Fiber Fabric (8 sheets of Uni or Bi)
• 747 Epoxy Resin Part A Base (128 oz 3:1 Mix)
• 747 Epoxy Resin Part B Hardener (43 oz 1:3 Mix)
• Unidirectional 12” x 90”
• Bidirectional 5.5” x 90”

STORAGE

Keep Fiberlock™ resin components tightly sealed in their original containers until ready for use. Store at 60-80°F to facilitate handling and workability. Properly stored, Fiberlock™ resin has a shelf life of 12 months. All resins should be conditioned to 70-75°F prior to use for best viscosity, application and wet out capability. Fabrics should be kept boxed or bagged and away from direct sunlight, moisture or dirt/dust.

PROPERTIES

SURFACE PREPARATION

Concrete should be a minimum 50°F, adequately cured, possess adequate integrity and not be expelling excess water or hydration. A rule of thumb for cure of new concrete is 28 days cure at 70°F but that is not an assurance that the concrete has achieved adequate physical properties.

The prepared area should extend 2 inches (on all sides) beyond the width of the carbon fabric. In general, the surface must be dry, clean, free from dust, paint, coating, oil or dirt and free from frost. For bumps, fins and protrusions use hammer, sand blasting, pressure washing, shot blasting, grinding or other approved mechanical means to achieve an open-pore texture with a CSP (concrete surface profile) 3 or better per ICI Guideline 310.2R. Surface should be wiped with clean cloth after grinding, blasting, brushing surface to remove dust particles. Uneven surfaces (voids) and mortar joints must be filled with Gateway Composites 777 Fiberlock™ Epoxy Adhesive/Filler Compound. (2 part 1:1 mix ratio). 777 Filler Compound should be pressed into the voids/cracks and feathered for smooth surface. A smooth surface is critical for fabric bonding. Uneven surface can result in voids between fabric and substrate which leads to premature delamination of composite.

RESIN MIXING

Gateway Composites 747 Fiberlock™ Resin is a two part epoxy system with a mix ratio of 3:1 (3 parts base epoxy, 1 part hardener). Epoxies generate heat during mixing and curing cycle, components must be mixed accurately and completely. Use a measured mixing container and roller pan with a high surface to volume ratio that will help minimize heat generation. Mix and keep resins from direct sunlight. Mix using a slow speed paddle (Jiffy type) at 400 rpm for 3-5 minutes. When operating the mixer, avoid plunging it up and down in the bucket. This can fold air into the resin, which may cause bubbles to form in the coating after it has been applied. Be especially careful not to allow water to enter the mix. The working time for Fiberlock™ resin is 25-30 minutes at 70°F, mix only necessary amount to be applied within 30 minutes (15 oz Base Part A and 5 oz Hardener Part B for 8 ft of carbon fiber application). Working time will be longer at cooler temperatures and will be much shorter at higher temperatures.

APPLICATION

Apply one coat of mixed Fiberlock™ resin to saturate and cover concrete (approx. 20 mil thickness) with ¼” nap roller. Make sure to cover complete application area (no dry concrete visible where carbon fiber will be applied, press roller firmly onto surface for good coverage). Place cut fabric piece against wall so fiber orientation is from top to bottom (vertical). Use hands to gently press fabric into resin for adhesion. Apply second coat of resin extending beyond dimensions of carbon fabric by 2 inches. Press firmly with roller keeping in same direction as fibers for maximum saturation and wet-out of fabric.

SAFETY & FIRST AID

Avoid breathing vapors. Avoid contact with skin and eyes. Rubber gloves, mask and goggles are recommended for safety. Review Safety Data Sheets (SDS) prior to use.

RECOMMENDED TOOLS

STEP BY STEP INSTRUCTION

1. Locate and mark the positions of the wall strips by placing a mark 2 feet from each end of the wall and measuring inward mark every 4 feet center. *For a cleaner and professional finish look, measure 8 inches from each side of center mark for 12 inch wide carbon fabric and 4 inches wide for 6 inch wide carbon fabric. Apply painters tape from top to bottom at each mark which can be removed at end of step 8 for cleanliness.
2. Using a grinder with 5” diamond wheel, grind area where the wall strips are to be placed. Remove any protrusions with a grinder or hammer. Brush area removing all debris, paint, coating, oil, and dirt. Make sure the wall is dry.
3. Measure from the top of the wall to the bottom and cut across the width of the carbon fiber so each wall strip measures identical length needed. Cut the number of wall strips needed for the horizontal crack and place near working area.
4. As necessary, fill all cracks, joints and voids, where the wall strips will be placed, using the 777 Epoxy filler compound. Feather/trowel for smooth surface. A smooth surface is critical for proper adhesion. Voids or bumps will create voids which result in poor bonding of composite to structure.
5. Mix 15 oz. “747 Part A Epoxy” with 5 oz. “747 Part B Hardener” in a dry clean disposable bucket. Mix thoroughly. Pour resin/hardener mixture into a disposable paint roller tray.
6. With a ¼” nap roller, start at the top of the wall and apply resin/hardener mixture to the area where the wall strip will be placed. Apply resin to area 2 inches wider on all sides than the fabric width. Use painters tape as edge guide.
7. With the carbon fiber wall strips at a 90-degree angle across the horizontal crack, lay the wall strip from the top to the bottom. Wearing rubber gloves on your hands, start at the top of the wall strip and slide hands down the wall strip using pressure. This will adhere the wall strip to the resin coated concrete.
8. Rolling in the same direction as the carbon fiber wall strip, apply one more coat of the resin/hardener mixture with roller in the same direction as the fiber (this aids in fabric wet-out). Do not roll back and forth across the fiber direction. Make sure the carbon fiber wall strips are laying flat against the concrete. Use firm pressure to achieve good wet-out of carbon fabric. Remove painters tape.
9. Repeat steps 5 through 8 until the wall has been covered with the carbon fiber wall strips needed.
10. Clean up and dispose of excess materials as stated in the SDS sheets.
11. * 4 foot center is a typical recommendation. Individual wall characteristics (thickness, cracking, deflection, etc.) can influence spacing and should be used by a licensed engineer to calculate spacing per ACI 440 guidelines for optimum results.

It is the responsibility of each purchaser and end user of each Fiberlock™ product to determine the suitability of the Product for its intended use. Prior to using any Product, consult a qualified design professional for advice regarding the suitability and use and application of the Product, including whether the capacity of any structural element may be impacted by a repair. “Dry Fiber Properties” are confirmed by Certificate from the fiber manufacturer. “Laminate Properties” are to be used by technically skilled persons at their own discretion and risk. The properties do not constitute any warranty or guarantee. AJI values are for material selection purposes only. An externally applied CFRP system is a vapor barrier. Consult with a licensed, professional engineer to evaluate the results of encapsulating a porous substrate. The installer must read, understand and follow all written instructions, and warnings contained on the product label(s), Product Data Sheet(s), Safety Data Sheet(s) and the www.gatewaycomposites.com website prior to use. For use only by qualified applicators.