User Manual And Product Catalogue - WEST SYSTEM
Over Thirty Five Years of Epoxy Technology and InnovationUser Manual andProduct Catalogue
ContentsUSER MANUALWEST SYSTEM User Manual1. User Manual Introduction12. Handling Epoxy2.1Epoxy Safety2.2Clean Up2.3Epoxy Chemistry2.4Dispensing and Mixing2.5Adding Fillers and Additives4455793. Basic Techniques3.1Surface Preparation3.2Bonding (Gluing)3.3Bonding with Fillets3.4Bonding Fasteners and Hardware3.5Laminating3.6Fairing3.7Applying Woven Cloth and Tape3.8Epoxy Barrier Coating3.9Barrier Coating for Osmosis Repair3.10Final Surface Preparation3.11Finish Coatings1111141617202122262728294. Cold Temperature Bonding4.1Chemical Characteristics4.2Working Properties4.3Cold Weather Techniques4.4Cold Weather Storage31313132335. Product Selection and Estimating Guides346. Problem Solver367. The Products39PRODUCT GUIDE 8. Product Guide8.1WEST SYSTEM Resins and Hardeners8.2Epoxy Dispensers8.3Repair Packs and Resin Packs8.4WEST SYSTEM Packs8.5Fillers8.6Additives8.7Reinforcing Materials8.8Application Tools8.9Instructional Publications8.10Instructional Videos4040424343444546485151Back to Contents
1. USER MANUAL INTRODUCTIONWEST SYSTEM Brand epoxy is a versatile, high-quality, two-part epoxy thatis easily modified for a wide range of coating and adhesive applications. It isused for construction and repairs requiring superior moisture resistance andhigh strength. Originally developed by Gougeon Brothers Inc. over 35 years agofor the production of wooden boats, WEST SYSTEM epoxy products are nowrecognised throughout the marine industry and are in everyday use for the repairand construction of fibreglass, wood, aluminium, steel, composite and ferrocementvessels. The knowledge that the WEST SYSTEM epoxy is designed for themarine environment - a particularly harsh and demanding requirement - promotesenormous confidence in the product range and, in more recent years, WESTSYSTEM epoxy has been used extensively in the construction industry, modelmaking and the DIY market for many applications.(See Our Booklet – “Other Uses-Suggestions for Household Repair”).This Manual is designed tohelp you become familiar withWEST SYSTEM products andto use them effectively. It alsoprovidesinformationaboutsafety, handling and the basictechniques of epoxy use whichwill allow the WEST SYSTEMproducts to be tailored to yourexact repair and constructionneeds. These techniques areused in a wide range of repairand building procedures suchas those described in detail inWEST SYSTEM instructionalpublications and videos.The Product Guide givesWESTSYSTEMWEST SYSTEM User Manuala complete description of theWESTSYSTEMproducts,including selection and coverageguides, to assist in choosingthe most appropriate productsand package sizes for the job inhand.productsare available from quality marinechandleries throughout the world.For the name of your nearestchandlery or for additionaltechnical, product, or safetyinformation, contact WessexResins and Adhesives Limited oryour local distributor.Back to ContentsUser Manual 1
Why WEST SYSTEM brand epoxy?WEST SYSTEM User ManualAll epoxies are different. Epoxy brands vary considerably in their formulations,quality of raw materials and their suitability for marine and other extremeenvironments. It is not difficult to market a general purpose epoxy for the marineindustry or to formulate a product having some favourable characteristics whilstsacrificing other important physical properties.However, it is much more difficultbalancing all the physical andmechanical properties necessaryfor a versatile, high qualitymarine epoxy. Defining therequired performance criteriaand designing a formula tomeet those criteria requiresgood chemistry, rigorous testprogrammes, extensive fieldtrials, continuing contact with theindustry and direct experience withtoday’s high-performance boat builders.Balanced epoxy performanceWEST SYSTEM epoxy is designed for boatbuilding and repair by experiencedepoxy formulators who know the engineering and the chemistry required fortoday’s high-performance composite structures. With more than thirty-five yearsof developing marine epoxies, Gougeon Brothers Inc. and Wessex Resins &Adhesives Ltd. have continued to formulate, test and improve WEST SYSTEMresin and hardeners to create the most reliable and well balanced epoxy systemavailable today.Potential resin and hardener formulae, ingredients and combinations are tested tocompare fatigue strength, compression strength, glass transition temperature andpeak exotherm. Additionally, samples are tested for hardness, tensile strength,tensile elongation, tensile modulus, flexural strength, flexural modulus, heatdeflection temperature, impact resistance and moisture exclusion effectiveness.Such thorough testing ensures that any change in a formulation will improve atleast one characteristic of the product without diminishing the other properties.Comprehensive testingContinuing research and comprehensive testing are essential for the developmentof both improved epoxy formulations and better construction and repair methods.In addition, the material test laboratory also conducts extensive test programmesto support builders, designers and industry on specific projects.Standard BS EN ISO Test Procedures are normally used to evaluate the physicalproperties of adhesives and composite laminates but, occasionally, the laboratoryis called upon to evaluate to a particular DIN or ASTM Standard.The information provided by a comprehensive test programme and feedbackfrom customers contributes to a data base on epoxies and epoxy composites thatUser Manual 2Back to Contents
is continuously growing. This knowledge is invaluable for achieving the properbalance of properties required for a versatile, high-quality marine epoxy andensures the information is up-to-date and reliable.The WEST SYSTEM epoxies have been approved by theLloyds Register of Shipping following an extensive testprogramme which involved bonding wood, glass reinforcedplastic (GRP), mild steel, aluminium and combinations thereof.Specific details of this accreditation are available on request.Technical supportWEST SYSTEM User ManualTo ensure that the ultimate characteristics and versatility of the WEST SYSTEMepoxy are achieved, Wessex Resins provides one other important ingredient– technical service. Whether the project in hand is large or small, WEST SYSTEMtechnical publications and videos offered in this guide provide detailed proceduresand instructions for specific repair and construction applications. Further assistancecan be obtained by writing or contacting our technical staff either via our TechnicalSupport Helpline: 44 (0) 870 770 1030 or by email: techinfo@wessex-resins.com– we are always interested in your projects whether it is a major repair on a boat,replacing a rotting window sill at home or a simple DIY job in the garage.Back to ContentsUser Manual 3
2. HANDLING EPOXYWEST SYSTEM User ManualThis section explains the fundamentals of epoxy safety, curing and the steps forproper dispensing, mixing and adding fillers to ensure that every batch cures to ahigh strength solid.2.1 Epoxy SafetyEpoxies are safe when handled properly but it is essential to understand thehazards and take precautions to avoid them.HazardsThe primary hazard associated with epoxy involves skin contact. WEST SYSTEMResin may cause moderate skin irritation; WEST SYSTEM Hardeners may causesevere skin irritation. Resins and hardeners are also sensitisers and may cause anallergic reaction but, from our experience, most people are not sensitive to WESTSYSTEM Resin and Hardeners. These hazards decrease as resin/hardener mixesreach full cure but it is important to appreciate that the hazards also apply to thesanding dust from partially cured epoxy. Please refer to the Material Safety DataSheets for specific product warnings and safety information.Precautions1.Avoid contact with resin, hardeners, mixed epoxy and sanding dust. Wearprotective gloves and clothing when handling WEST SYSTEM materials. WESTSYSTEM 831 Barrier Cream provides additional protection for sensitive skin andallergies. DO NOT use solvents to remove epoxy from the skin. Immediately afterskin contact with resin, hardeners, sanding dust from epoxy and/or solvents, useWEST SYSTEM 820 Resin Removing Cream for the initial clean-up, followed by awash with soap and warm water.If a skin rash develops while working with epoxy, stop using the product untilthe rash completely disappears. If problems persist when work is resumed,discontinue use and consult a doctor.2.Protect your eyes from contact with resin, hardeners, mixed epoxy, andsanding dust by wearing appropriate eye protection. If contact occurs, immediatelyflush the eyes with water for 15 minutes. If discomfort persists, seek medicalattention.3.Avoid breathing concentrated vapours and sanding dust. WEST SYSTEMepoxy vapours can build up in unvented spaces and ample ventilation must beprovided when working with epoxy in confined areas such as boat interiors. Whenadequate ventilation is not possible, wear an approved respirator.4.Avoid ingestion. Wash thoroughly after handling epoxy, especially beforeeating. If epoxy is swallowed, drink large quantities of water - DO NOT inducevomiting. Call a doctor immediately. Refer to First Aid procedures on the MaterialSafety Data Sheet.5.KEEP RESINS, HARDENERS, FILLERS AND SOLVENTS OUT OF THEREACH OF CHILDREN.User Manual 4Back to Contents
For additional safety information or data, write to: EPOXY SAFETY, WessexResins & Adhesives Limited, Cupernham House, Cupernham Lane, Romsey,Hampshire SO51 7LF2.2 Clean UpContain spills with sand, clay or other inert absorbent materials and use a scraperto collect as much material as possible. Follow up with absorbent towels.DO NOT use either sawdust or other fine cellulose materials to absorb hardenersand/or dispose of hardener in waste containing sawdust or other fine cellulosematerials—spontaneous combustion may occur.Clean resin, or mixed epoxy residue or uncured epoxy with WEST SYSTEM 850Cleaning Solvent. Clean hardener residue with warm soapy water.Dispose of resin, hardener and empty containers safely in accord with localdisposal regulations.DO NOT dispose of resin or hardener in a liquid state. Waste resin and hardenershould be mixed and cured (in small quantities) to a non-hazardous inert solid.CAUTION! Large volumes of curing epoxy can become hot enough toignite surrounding combustible materials and produce hazardous fumes.Place containers of mixed epoxy in a safe and ventilated area away fromworkers and combustible materials. Dispose of the solid mass when the cure iscomplete and the mass has cooled. Comply with the local disposal regulations2.3 Epoxy ChemistryOpen time and cure time determine the build and repair operations. Open timedictates the time available for mixing, application, smoothing, shaping, assemblyand clamping. Cure time dictates the time before removing clamps, abrading orproceeding to the next step in the project. Three factors determine the open timeand cure time of an epoxy mix – hardener cure speed, epoxy temperature andvolume of mix. Cure time is shorter when theepoxy is warmer. Cure time is longer when theepoxy is cooler.Back to ContentsFigure 1 As it cures,mixed epoxy passesfrom a liquid state,through a gel state, toa solid state.User Manual 5WEST SYSTEM User ManualUnderstanding cure time
a) Hardener speedWEST SYSTEM User ManualEach hardener has an ideal temperature cure range. At any given temperatureeach resin/hardener combination will go through the same cure stages but atdifferent rates. Select the hardener that gives adequate working time for the job inhand at the temperature and conditions under which the work is to be completed.The Product Guide describes hardener pot lives and cure times.Pot life is a term used to compare the cure speeds of different hardeners. It is theperiod of time a specific mass of mixed resin and hardener remains a liquid at aparticular temperature e.g. a 100g mass of an epoxy mix in a standard container at25 C is a routine quality control test procedure.Because pot life is a measure of the speed of cure of a specific mass (volume) ofepoxy rather than a thin film, the pot life of a resin/hardener mix is much shorterthan its open time.b) Epoxy temperatureThe warmer the temperature the faster an epoxy mix will cure (Figure 1). Thetemperature at which epoxy cures is determined by the ambient temperature plusthe exothermic heat generated by the reaction.Ambient temperature is the temperature of the air and/or the material in contactwith the epoxy. Epoxy cures faster when the ambient temperature is warmer.c) The volume of mixed epoxyMixing resin and hardener together creates an exothermic (heat producing)reaction. Always mix small batches of epoxy because the greater the quantity, themore heat generated, the shorter the pot life and cure time. In a larger volume,more heat is retained, causing a faster reaction and yet more heat e.g. a plasticmixing cup containing, say, a 200g mix. can generate enough heat to melt the cup.However, if the same quantity is spread into a thin layer, the exothermic heat is notproduced as quickly and the cure time of the epoxy is determined by the ambienttemperature.Controlling cure timeIn warm conditions use a slower hardener to increase the open time. Mixsmaller batches that can be used quickly or pour the epoxy mix into a containerwith greater surface area e.g. a roller pan, thereby spreading out the epoxy intoa thin film and extending the open time. After thorough mixing, the sooner theepoxy is transferred or applied, the more open time is available for coating, lay-upor assembly.In cool conditions use a faster hardener and employ a hot air gun, a heat lampor other heat source to warm the resin and hardener before mixing and/or after theepoxy is applied. At room temperature, additional heat is useful when a quickercure is desired. NOTE! Unvented kerosene or propane heaters can inhibit thecure of epoxy and contaminate epoxy surfaces with unburned hydrocarbons.User Manual 6Back to Contents
CAUTION! Warming a resin/hardener mix will lower its viscosity, allowingthe epoxy to run or sag more easily on vertical surfaces. In addition,heating epoxy applied to a porous substrate (soft wood or low densitycore material) may cause the substrate to “out-gas” and form bubbles in the epoxycoating. To avoid out-gassing, wait until the epoxy coating has gelled beforewarming it. Never heat mixed epoxy in a liquid state over 50 C.Regardless of the steps taken to control the cure time, thorough planning of theapplication and assembly will allow maximum use of the open time and cure timeof the epoxy mix.Cure stages of epoxyMixing epoxy resin and hardener begins a chemical reaction that transforms thecombined liquid components into a solid. As it cures, the epoxy passes from theliquid state , through a gel stage before it reaches a solid state. (Figure 1)1.Liquid – Open timeOpen time (also working time) is the period, after mixing, that the resin/hardenermix remains a liquid and is workable and suitable for application. All assemblyand clamping should take place during this period to ensure a dependable bondis achieved.2.Gel – Initial cure phaseThe mix passes into an initial cure phase (also known as the “Green Stage”) whenit begins to gel. The epoxy is no longer workable and will progress from a tackyconsistency to the firmness of hard rubber. An indent can be made with the thumbnail and it is too soft to dry sand.While the epoxy is tacky, a new application of epoxy will chemically link with it, sothe surface may be bonded or recoated without sanding. This ability diminishesas the mix approaches the final cure phase.Solid – Final cure phaseThe epoxy mix has cured to a solid state and can be dry sanded and shaped. Itis no longer possible to indent the surface with the thumb nail. At this stage, theepoxy has reached 90% of its ultimate strength, so clamps can be removed. Themix will continue to cure over the next few days at room temperature.A new application of epoxy will no longer chemically link to it, so the surfacemust be thoroughly washed and sanded before recoating to achieve a goodmechanical, secondary bond. See Surface Preparation – page 11.2.4 Dispensing and MixingCareful measuring of resin and hardener and thorough mixing of the twocomponents are essential for a proper cure. Whether the resin/hardener mix isapplied as a coating or modified with fillers or additives, observing the followingprocedures will ensure a controlled and thorough chemical transition to a highstrength epoxy solid.Back to ContentsUser Manual 7WEST SYSTEM User Manual3.
DispensingWEST SYSTEM User ManualDispense the correct proportions of resin and hardener into a clean plastic, metalor wax-free paper container (Figure 2). Do not use glass or foam containersbecause of the potential hazard from exothermic heat build-up. DO NOT attemptto adjust the cure time by altering the mix ratio. An accurate ratio is essential for aproper cure and full development of physical properties.Figure 2 Dispense the correctproportions of resin and hardener.Dispensing with Mini pumpsMost problems related to the curing of epoxy can be traced to the wrong ratio ofresin and hardener. To simplify metering, use calibrated WEST SYSTEM MiniPumps to dispense the correct working ratio of resin and hardener. (For one fullpump stroke of resin use one full pump stroke of hardener.) Depress each pumphead fully and allow the head to return completely before beginning the nextstroke. Partial strokes will give an incorrect ratio. Read the pump instructionsbefore using the pumps and verify the correct ratio before using the first mix on aproject. Recheck the ratio whenever curing problems are experienced. One fulldepression of each pump will give approximately 30g of mixed epoxy.1 stroke1 stroke ResinHardenerWith Mini Pumps One full pump strokeof resin for onefull pump stroke ofhardener will give thecorrect ratio.Dispensing without Mini Pumps—Weight/volume measureTo measure 105 Resin and 205 or 206 Hardener by weight, combine five partsresin with one part hardener. Small quanities can be mixed by volume at the sameratio. To measure 105 Resin and 207 or 209 Hardener by volume, combine threeparts resin with one part hardener (by weight, 3.5 parts resin : 1 part hardener).First time usersIf using WEST SYSTEM epoxy for the first time, begin with a small test batch toget the feel for the mixing and curing process before applying a mix to the job inhand. This will demonstrate the open time for the resin/hardener mix at the presentambient temperature and give assurance that the mix ratio is correctly metered.Mix small batches until confident of the handling characteristics of the epoxy.User Manual 8Back to Contents
MixingThoroughly blend the two ingredients for 2 minutes - longer in cooler temperatures(Figure 3). Scrape the sides and bottom of the pot when mixing. If using the mixfor coating, after mixing, quickly pour into a roller pan to extend the open time.scrape cornersFigure 3 Stir resin and hardenerthoroughly together for 2 minutes,longer in cooler temperatures.WARNING! Curing epoxy generates heat. Do not fill or cast layers ofepoxy thicker than 10 to 12mm – thinner if enclosed by foam or otherinsulating material. If left to stand for the full pot life in a plastic mixingcup, the mixed epoxy will generate enough heat to melt the plastic. If a pot ofmixed epoxy begins to exotherm (heat up), quickly move it outdoors. Avoidbreathing the fumes. Do not dispose of the mixture until the reaction is completeand the material has cooled.2.5 Adding Fillers and AdditivesFillersAfter selecting an appropriate filler for the job in hand (selection guide - page 34),use it to thicken the epoxy to the desired consistency. The viscosity or thickness ofa mix required for a specific job is controlled by the amount of filler added. Thereis no strict formula or measuring invo
User Manual and Product Catalogue Over Thirty Five Years of Epoxy Technology and Innovation. SYSTEM User Manual WEST Back to Content s Contents USER MANUAL 1. User Manual Introduction 1 2. Handling Epoxy 4 2.1 Epoxy Safety 4 2.2 Clean Up 5 2.3 Epoxy Chemistry 5 2.4 Dispensing and Mixing 7 .
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