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CARBON FIBER SHEET PROCEDURES

General installation procedures are given in the steps below. Specific installation procedures
for columns, beams, walls, and slabs are included under Application Procedures. This
document should be read in its entirety before beginning any project.

A. SAFETY

 All MSDS sheets are to be posted at the site.


 SAFETY POLICY issued by Installation Company to be posted at site.
 All protective equipment required for safe completion of the job will be worn.

B. PRE-PROJECT PREPARATION

 Obtain all equipment and materials as per checklist and any special project
requirements with includes testing of the actual Compressive Strength of the substrate
at site using rebound hammer (Third Party).

C. SURFACE PREPARATION

 Surfaces where the Carbon Fiber Sheet is to be applied must be sound. Concrete spalls
and delamination’s must be repaired.
 Inject cracks. Cracks greater than 0.25mm (0.010 in.) must be stabilized using epoxy
injection methods.
 Fill honeycombs and bug holes with structural concrete putty/epoxy.
 Remove form lines, sharp edges and protrusions by grinding or filling with putty.
Ridges greater than 5mm may need to be ground down as per engineer’s inspection.
 Surface undulations greater than 15mm over 1m (or approximately 0.5 inches over 3
feet) may need to be smoothed as per engineer’s inspection.
 Radius corners perpendicular to the fiber orientation by grinding as per the project
specifications.
 Ensure and open pore structure of the substrate by either sandblasting, high-pressure
water blasting or wire brushing.

 Surfaces and (anchor holes) must be cleaned of dust and debris by blowing with air or
broom cleaning.
 Drill anchor holes (if required) as per the specifications.
 The substrate should be dry before the application of the Carbon Fiber Sheet.
D. PREPARATION WORK FOR PROJECT

 Review project specifications in detail.


 Pre-cut fabric with off-site labor where possible.
 Check surface-prep of substrate to make sure all patchwork is complete and cured.

E. SET-UP OF SATURATOR AND AUTOMATIC MIXING UNIT (when used)

 Set-up of Automatic Mixing Unit shall be supervised and checked by the properly
trained foreman.
 Equipment should be located in a well- ventilated and well- lighted area.
 Set-up of Saturator shall be supervised and checked by the properly trained foreman as
per the manufacturer’s instructions. The saturator gap should be set to achieve the
following ratios:
 Carbon fabrics/all epoxy resins: as per manufacturer/supplier specifications.

F. DETERMINING CORRECT FABRIC TO RESIN RATIOS

 For quality control purposes, the proper resin content can be checked by weighing a
small sample of the dry fabric prior to saturation and then right after saturation. The
proper weight and size measurements are given below for Carbon Fiber Sheet.

G. EPOXY MIXING PROCEDURES

 Pre-mix each component. Mix entire unit. Do not batch down. Pour contents of Part B
into Part A. Mix thoroughly for 5 minutes on low speed (400-600 rpm) using a paddle
style mixer until uniformly blended.

H. APPLICATION PROCEDURES

 Beginning with a clean work area (free of dust and debris)


 Using a ROLLER, prime the area to be wrapped by applying one coat of Carbon Fiber
Epoxy. Wait approximately 1 hour (½ hour minimum) to allow the epoxy to penetrate
the substrate pores and to become “tacky”.
 Apply the Carbon Fiber Sheet to the element to be strengthened as per the engineering
drawings.
 For maximum adhesion of vertical or overhead applications, apply the layers of Carbon
Fiber Sheet individually, waiting approximately 1 hour (½ hour minimum) in between
layers. Columns may be continuously wrapped.
 Apply Carbon Fiber Sheet with uniform and smooth pressure either with a stiff spatula
or a surface roller removing and air bubbles caught beneath the fabric surface. More
resin may be added to the applied Carbon Fiber Sheet with a wetted roller if necessary.
 Apply final coat of Carbon Fiber Epoxy.

FOR COLUMNS
 Wrap the column with the specified number of wraps as
calculated and indicated on the specification.
Wrap TOP first; BOTTOM second or as per project
specifications. Sequence to be advised on daily
work sheet for each column. Follow approved drawings.
 While continuously wrapping, apply Carbon Fiber Sheet
with uniform and smooth pressure either with a
stiff spatula or a surface roller, securing and
smoothing each layer.

FOR BEAMS (INCLUDING SHEAR STRENGTHENING)

 Wrap the beam with the specified number of wraps as


calculated and indicated on the specification.
Sequence to be advised on daily work sheet for each beam.
Follow approved drawings.
 Apply shear strengthening layers on top of the flexural
strengthening layers or as per engineering drawings.
This method helps to secure the ends of the flexural
strengthening.

I. FINISH

 Cover top and bottom of fiber or cut trim for aesthetics.


 Paint as specified. Always wait until epoxy final coat is dry tacky to touch. If over 72
hours, surface must be brush blasted.

J. CLEAN UP

 Clean all equipment each day. Uncured epoxy should be wiped up with a rags wetted
with MEK solvent (or equivalent).
 If there is any uncured epoxy left at the end of the day, pour it out thinly on a flat
polyethylene lined surface where it will cure safely overnight.

K. QUALITY CONTROL PROCEDURES (See specification)

 Check temperature of Epoxy A component


 Check ratio of epoxy at the beginning of each day.
 Two (2) Samples (two layers) each day or as per specification.
 Measure fiber square meters or footage and amount of epoxy used each day.
 Check to make sure fabric is applied uniform and smooth.