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Laminating and Casting

Epoxy Systems

Technical Bulletin

Precision Epoxy Products
a division of : Rock Art, Ltd.
4279 Midway Drive
Douglasville, Georgia 30134

Phone : (770) 489-0340

    Description:  Decoupage Epoxy, Rigid Casting Series Epoxies, Deep Casting Series Epoxies and Floor Plate Epoxies are two component, 100 % solids epoxy systems used for laminating, casting, leveling, electronics potting, etc. These epoxies offer a wide range of liquid and solid state properties to suit your application needs with regards to viscosity, rates of cure, hardness, flexibility, bond strength and chemical resistance. Another consideration that determines product selection is whether the project requires a water clear, opaque or pigmented system.

Application :

    Surface Preparation:  Surfaces that are being bonded to should be clean, dusted and free of grease, oil, wax or silicone. A final tack-ragging with denatured alcohol is recommended prior to application. When laminating over wood or any porous type surface, a sealer coat should be applied first to block air migration into lamination coat. Pictures, thin art work, newspaper clippings, etc. can be bonded down into sealer coat prior to first pour. This will eliminate ends from curling or floating during lamination coat. When pouring a project that is flowing over the outer edges (not a contained area), plastic sheeting will need to be in place to catch epoxy run off.

When casting, a mold release agent must be used to prevent casting resin from bonding to mold. Vaseline, Pam, an oil base product, spray silicone, etc. all work well. Experiment to find the type mold release agent that gives the best results for your application.

    Coverage:  When casting or electronics potting, you will be dealing with cubic volume, one gallon of epoxy mix will fill 231 cubic inches. For flat surface laminating, coverage will be as follows :

    Measure:  Follow mix ratio as described on product's label. The mix ratio will be by volume and it cannot be over emphasized that proper mix ratio be strictly adhered to. Do Not alter the mix ratio for any reason. Should measuring of components be done by weight instead of volume, contact Precision Epoxy for the component weights of the product you are using. Calibrated measuring units of various sizes are available from Precision Epoxy.

    Mixing:  Mix the measured Parts 'A' and 'B' components in a clean, dry container. Components can be stirred until material is thoroughly blended using a flat stir stick for 6 minutes. This is a primitive method and is not recommended for normal applications. Material should be blended with an electric drill motor and the appropriate size mixing blade for 2 to 4 minutes depending on your batch size. Proper mixing blades are available from Precision Epoxy. If material is not mixed thoroughly, final pour could have soft or sticky spots or a marbling appearance on the surface. Be sure and scrape sides and bottom of mixing container to include all of both components into the blend. Avoid whipping air into material while mixing.

    Pouring:  Pour material onto prepared surface or into mold in such a fashion as to aid in leveling. Spreading material with a margin trowel, spatula or gauge rake will help to quicken coverage and leveling. For laminations that include wrapping the edges, be sure to have a way to catch run-off. Attention to edges will be needed to help material obtain uniform coverage. You must have object being laminated raised in such a fashion so it does not lay in the epoxy run-off puddle.

    Torching:  With a standard propane torch, wave the blue flame like a wand slightly above the epoxy pour to break the surface tension and release air bubbles that have migrated to the surface but have not released. Do not hold the torch in one spot to long, keep it moving with even strokes. The epoxy is not flammable, however; should flame touch the epoxy surface it can leave a discolored or sooty mark. Should this happen, simply dip out the burn mark with your spreading tool and continue. Any bugs or debris that might find their way into your pour can also be dipped out in the same manner within your 'Open Time' window and the epoxy will self level back smooth again. Air bubbles are created when measuring components, mixing components, pouring mixed epoxy and from elements created by the surface you are pouring onto. Minimizing the sources of air will help with clear coat pours, however, clear coat pours will always need torching. If you are pouring with a pigmented epoxy color system, the epoxy can be formulated with de-air additives that will allow all entrained air to release on its own and eliminate the need for torching.

    Final:  There will be a point that you will have to 'Leave It Alone' and let it cure. If flaws exist the next day, simply cut or sand them out and re-pour. A dust cover in some cases is essential in order to achieve a perfect finish. For laminated objects with wrapped edges, drips on bottom can be sanded flush after epoxy has properly cured.

The following are our standard Epoxy Products suitable for Casting and Laminating.
We also offer Modified Versions and Custom Formulations.

All mix ratios are by volume.

•   DECO  (mix ratio 1:1 / A:B)
  Decoupage Epoxy is a clear self-leveling system designed for laminating bar tops, table or counter tops, pictures, art work, clocks, cypress, etc. This system offers a slow rate of cure making it ideal for the novice user or for tedious application environments where more time is helpful.
  
  

•   Rigid Casting Epoxy Series  is a fluid system used for structural bonding, laminating, art casting, electronics potting, etc. The RC Series epoxies are selected to suit the application environment and temperature. They are available in thick or thin viscosity versions to suit a wide range of applications and rates of cure. These systems are non-conductive, high strength, high heat distortion, self-leveling epoxies and are available in clear or pigmented versions.
  
  

•   RC-52  (mix ratio 1:1 / A:B)
  Rigid Casting Epoxy - 52 is the 'Fast Cure' of the series for specialized applications. This system has a pot life of ten minutes and reaches handling strength in one hour at 77 degrees F.
  
  

•   RC-53  (mix ratio 2:1 / A:B)
  Rigid Casting Epoxy - 53 is for use in applications requiring a rapid cure or for use at lower application temperatures. This system has high strength properties without being brittle, making it ideal for specialized casting.
  
  

•   RC-55  (mix ratio 1:1 / A:B)
  Rigid Casting Epoxy - 55 is the most widely used of the RC series. The 45 minute pot life at 75 degrees F seems to make it suitable for a wide range of applications.
  
  

•   RC-57  (mix ratio 2:1 / A:B)
  Rigid Casting Epoxy - 57 has the slowest rate of cure for use at higher application temperatures or tedious applications where more open time would be useful.
  
  

•   RC-190  (mix ratio 2:1 / A:B)
  Rigid Casting Epoxy - 190 is a special 'Armor Plating' formulation to satisfy special needs of the electronics potting industry. This system is extremely hard and durable making it virtually impossible to be broken down to reveal circuitry within the casting. Available in a thick black color to further hide contents within the casting.

•   Deep Casting Epoxy Series  parallel the Rigid Casting Series Epoxies. The DC Series epoxies contain a filler to eliminate 'Boiling' in large deep (3/4" plus) pours and are selected to suit the application environment and temperature. They are available in thick or thin viscosity versions to suit a wide range of applications and rates of cure. These systems are non-conductive, high strength, high heat distortion, self-leveling epoxies and are available in opaque or pigmented versions.
  
  

•   DC-52  (mix ratio 1:1 / A:B)
  Deep Casting Epoxy - 52 is the 'Fast Cure' of the series for specialized applications. This system has a pot life of ten minutes and reaches handling strength in one hour at 77 degrees F.
  
  

•   DC-53  (mix ratio 2:1 / A:B)
  Deep Casting Epoxy - 53 is for use in applications requiring a rapid cure or for use at lower application temperatures. This system has high strength properties without being brittle making it ideal for specialized casting.
  
  

•   DC-55  (mix ratio 1:1 / A:B)
  Deep Casting Epoxy - 55 is the most widely used of the DC series. The 45 minute pot life at 75 degrees F seems to make it suitable for a wide range of applications.
  
  

•   DC-57  (mix ratio 2:1 / A:B)
  Deep Casting Epoxy - 57 has the slowest rate of cure for use at higher application temperatures or tedious applications where more open time would be useful.

•   FS-190  (mix ratio 2:1 / A:B)
  Floor Sealer Epoxy is a high strength, water clear system for use as a roller applied sealant in Industrial Flooring, Quartz Flooring, Stained concrete sealer, Interior Riverstone Flooring, Broadcast Flooring applications and clear top coat applications. FS-190 is extremely durable, chemical resistant and can be used as a commercial grade Decoupage System or a Santex binder epoxy.
  
  

•   TC-200  (mix ratio 2:1 / A:B)
  Top Coat Epoxy is a pigmented, high strength, high build thixotropic industrial floor finish. It is extremely durable, chemical resistant with excellent scratch and impact resistance. Applied by brush/roller, squeegee or airless sprayer. Available in 16 standard colors with custom colors available upon request. TC-200 can be used as a colored Santex binder for troweled systems.
  
  

•   FP-80  (mix ratio 2:1 / A:B)
  Floor Plate Epoxy is a clear self-leveling system for use in Surface Plate applications. This system is extremely hard and can be used in industrial laminating applications that have harsh or punishing environments.
  
  

•   FP-85  (mix ratio 2:1 / A:B)
  Floor Plate Epoxy that is the pigmented version of the FP Series Epoxies for use in Surface Plate applications. Available in 14 standard colors with custom colors available upon request. Both Floor Plate Epoxies are extremely durable, chemical resistant with excellent scratch and impact resistance.
  
  

•   FP-90  (mix ratio 1:1 / A:B)
  Floor Plate Epoxy that is designed for use in the Aerospace Industry Test Bed applications. This 100% solids, zero VOC system has a very slow rate of cure to achieve the most level and flat surface area possible. The FP-90 provides a perfect surface that is unmatched and allows for the floating of air bearing devices with little to no drift while using minimal air pressure. Available in Black.

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Copyright 2010 Rock Art, Ltd.

Precision Epoxy Products
4279 Midway Drive
Douglasville, Georgia 30134
(770) 489-0340