PRECAST CONCRETE

MRA application with

a flat spraying nozzle.

Mould-release oil
application in precast
concrete

By using a waterbased emulsion

release oil, it can
be seen how much
MRA has been
applied, reducing
the uncertainties
of whether
theres been full
application or not.

Water-based emulsion oils

Mould-release agents (MRAs) are a critical
factor when it comes to precast concrete;
they can determine both the appearance
and durability of the finished units. There are
many different types of MRAs on the market
including solvent-based, full oil-based and
water-based emulsion oils, all of which are
used within the precast industry. The type
of MRA used in production is dependent
on many factors, including; preference,
application and, by far the most scrutinised,
price. Concrete report.

RAs must be applied in a thin uniform layer

covering the entire surface area of the unit,
which is to either be filled or that will come into
contact with the concrete. One of the most economical
ways of achieving a full uniform coverage would be to
use a spraying unit with a flat spraying nozzle.
MRAs can also be brush or rag applied. However, this
application is not the easiest or most economical way to
apply MRAs, as under- or over-application of release oil
can occur easily, which in turn, can have detrimental
effects on the resultant cast concrete.
Some of the problems that can be caused from
excessive amounts of release agent are discolouration,
surface retardation and dusting on the surface, none of
which will benefit the concrete and may result in units
being scrapped or in need of repair, providing a great
loss in both production time and an increase in wastage.

Water-based emulsion release

oils are now becoming more
favourable within the industry
due to their effectiveness and
ease of use. They are produced
by homogenisation, ie, mixing
oil and water, which gives the
emulsion oil a stable milky
white appearance. Emulsion oils
are also more environmentally
friendly than the full oil- and
solvent-based MRAs.
One of the many benefits of
using this type of mould-release
oil is that, because of the colour
and recommended sprayed
application, when sprayed onto
the mould or panel surface, a white speckled residue is
left showing where the oil has been applied. A further
ten to 30 minutes after application, depending on
temperature and relative humidity, the mould release
agent will show a transparent appearance. Within this
short time, the small oil drops will form a coherent
demoulding agent film (self-levelling effect).
By using a water-based emulsion release oil, it can
be seen how much MRA has been applied, reducing the
uncertainties of whether theres been full application
or not. Correct application will produce aesthetically
pleasing, problem-free products every time.
As good working practice, training and
demonstrations showing the application of these
emulsion MRAs should be provided by the company
supplying the material. This will ensure that the
advantages inherent in the product will be fully

Top: Too much release

agent has been applied.
Above: Correct amount
of release oil has been
applied.

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PRECAST CONCRETE

Below: After spraying,

a white speckled residue
is left.
Below centre: After a few
minutes the speckled
appearance begins to
disappear.
Bottom: After a further ten
to 30 minutes following
application, depending
on temperature, relative
humidity and wind, the
mould-release agent
will show a transparent
appearance.

achieved. As with any release agent, correct application

of the product is essential in order to maximise the
emulsion oils potential. It is important not to overdose
and in fact with certain emulsion types as little as 20g/
m2 may be required.
A further benefit to this type of MRA is that, because
it is visible upon the formwork when it is spray applied,
after training, an operative applying this material
consistently would be able to train his/her own eye and
movement to ensure correct application of the product.

Test results
Sika has carried out extensive laboratory and field test
evaluation of Sika Separol W water-based emulsion oil
with a full oil mould-release agent. One method involved

On the left of this picture, the mould was treated with traditional
full oil MRA and on the right with emulsion-based MRA. After only
ten seconds of vibration the emulsion oil has aided the compaction
of the concrete, whereas the full oil-based MRA would need further
compaction in order to achieve the same standard.

using a wet precast mix design, which was placed into

a transparent mould coated with the appropriate MRAs
and poker vibrated for five to ten seconds.
Results from these trials showed that after only ten
seconds the emulsion oil had aided the compaction of
the concrete, whereas the full oil-based MRA needed
further compaction in order to achieve the same
standard. Further benefits in using this type of MRA
included noise reduction, time saving, improved surface
appearance and increased production capabilities.
In tests carried out by Sika, Separol W water-based
emulsion oil MRA showed superior results when directly
compared to full oil MRA. Whichever MRA is chosen,
correct application is important. Too much mould oil
will cause many different problems to both the aesthetic
characteristics of the completed unit as well as the longterm durability of the actual concrete. It is therefore
always important to seek the correct advice when using
a new mould oil.

Follow the guidelines

Problems may not be initially seen while the concrete is
being placed possibly into thousands of moulds over a
24-hour period but the problems will be evident after
the concrete has set. Picture framing and retardation
of the concrete are just two examples of problems
arising from excessive mould-release oil application.
Manufacturers guidelines should be followed,
production trials should be carried out and even a toolbox talk and demonstration if available should be given
to all staff involved with the day-to-day running of a
concrete production line. Carrying out these simple
steps will ensure the correct oil type is chosen.
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