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Acrylic One - the technical stuff
HOW TO USE ACRYLIC ONE
Acrylic One must be carefully weighed and mixed. The mixing ratio of Acrylic One is 2 parts powder mixed with 1 part resin. Fill the beaker or bucket with the required amount of resin. Use the stainless steel High Shear Mixer to create a swirl. Then add the correct amount of powder into the swirl. Continue mixing until a smooth mixture is achieved without lumps and continue to mix for an additional 30 seconds approx. Ensure that none of the material sticks to the bottom and sides and that everything is included in the mixture.
The standard processing time after mixing is 20 minutes. When a shorter or longer processing time is required, this can be achieved by adding additives.
Acrylic One is a water-based product. Residual moisture must be allowed evaporate before obtaining the final result. The time needed for curing strongly depends on external factors, such as the dimension of the object, the temperature and humidity. When the object has been laminated or cast in a mould, it can be removed from the mould as soon as it is strong enough to cope with the forces present. The product will achieve its optimum strength outside of the mould.
Hands and skin can be washed using soap and water. Clean the equipment with water directly after use. We suggest that the brushes and equipment are cleaned in a bucket of water instead of in a wash basin, as the hardening process continues under water.
Laminating in a mould
When laminating Acrylic One in a mould, one needs to apply a gel coat first. As soon as the gel coat has dried (after 20 minutes), the object can be laminated immediately (within one hour for optimum adhesion) to ensure that an optimum adhesion between the gel coat and the laminate is achieved. Apply some Acrylic One in the mould and spread it equally over the surface. Then apply an Acrylic One triaxial fibre, which has been cut to size. Then apply Acrylic One again and work it into the triaxial fibre. Another layer of triaxial fibre can then be applied and the process is repeated in this way. Apply at least two layers of fibres, depending on the desired thickness and strength. Each layer of triaxial fibre results in a thickness of approximately 1 mm. Should the product require additional thickness, this can be achieved in the following ways:
By applying a layer of sandwich material (followed by 1 or more layers of triaxial fibre)
By applying a layer of Acrylic One mixed with nylon fibres and / or Poraver (expanded glass fibre, check for suitability for outdoor applications). Also followed by one or more layers of triaxial fibres.
Laminating around a product
Objects, for example made of modelling foam, can be coated with Acrylic One. First apply the Acrylic One onto the foam, followed by triaxial fibre. Work the Acrylic One in the triaxial fibre. Apply additional Acrylic One in dry spots. Apply at least two layers of triaxial fibre in this way. Each layer of triaxial fibre has a thickness of approximately 1 mm. Apply a layer of Acrylic One gel coat, based on Thix B or a mixture of Acrylic One and ATP powder, to achieve a smooth finish. It is possible to add a sealer layer for outdoor application. When the Acrylic One is just about dry, the surface can smoothed by using a wet sponge. After the object has fully cured, it can be sanded with wet waterproof sanding paper. If used for outdoor applications, the item is now ready for the application of a layer of sealant.
ADDITIVES & FILLERS
Acrylic One retarder can be used to lengthen the processing time. The retarder must always be added to the Acrylic One resin. Add a maximum of 2% of retarder to the total weight of the Acrylic One (resin + powder).
Acrylic One accelerator can be used to shorten the processing time and to increase productivity. Always add the accelerator to Acrylic One resin. Add a maximum of 1% accelerator to the total weight of the Acrylic One. The accelerator can also be used to correct any retarding effects of pigments and fillers.
Acrylic One Thix A is an additive to thicken the product and to give it a gel texture. The maximum achievable thickness is achieved by adding 2% to the total weight. This thixotropy agent is applied to produce gel coats and vertical or suspended parts.
Acrylic One Thix B is an additive to thicken the product to give it a paste structure. It can be used as a gel coat and as a paste to fill up textures. Acrylic One recommends that you do not use this product if the object is expected to be exposed to water, as this product’s water resistance is lower. Alternatively, you can apply a good protective layer.
ATP powder is a volume thickener. It enables the Acrylic One to be thickened to achieve a putty thickness. This putty can then be used to make the surface smooth and add the finish to the object. Be aware that ATP powder is not to be used in outdoor objects.
The Sealer is a water-based coating to protect the product against moisture and to give the product a weather resistant quality. TNO testing has shown that Acrylic One, if applied correctly with a Sealer, can last for approximately 30 years. We can supply you with the TNO report on request.
Acrylic One Sealer is a concentrated solution of acryl polymers in water. Always add 20% water to Acrylic One Sealer before use. The work surface must be free of wax, oil, dirt and dust. Apply the sealer with a brush, roller, brushing with a soft cloth or with a spray.
Acrylic One Sealer can be applied in one or more layers to improve the protective qualities of the layer. A second layer can be applied after 45 minutes, depending on the temperature and humidity. When applying the sealer with a soft cloth, one layer of Acrylic One Sealer will result in a satin matted gloss. More gloss is achieved by applying several layers. Minimum processing temperature: 10 °C. Average use: 8-10 m2 per litre
FILLERS, PIGMENTS & PAINTING
Acrylic One can be filled with various materials, such as pigments, sand and stone, organic fillers and lightweight fillers. This means the look of Acrylic One can be adjusted to the wishes and requirements of the user. A number of fillers impact the weather resistance.
Acrylic One can be painted after the item has dried, but can also be coloured beforehand by using pigments. The pigments are added into the resin before mixing. The maximum quantity of pigment is 2% of the total weight of the Acrylic One resin and powder combined.
Sand and quartz mixed in with Acrylic One results in a scratch resistant and hard top layer. A granito or granite look can be achieved by using different colours and sizes of quartz. If that is the look you are looking for, you need to sand the top layer after it has set to bring the stone to the surface and achieve a bigger contrast.
Poraver is a very lightweight filler. This product is used to make lightweight fillings in objects in instances when solid casting would be too heavy.
There are various metal powders available which can be added to Acrylic One to achieve metal effects. When you would like to achieve a rusted effect, use the iron power. Add an equal amount of iron powder as the amount of powder used to produce Acrylic One. When the applied layer had dried, it needs to be sanded using a wet scourer or waterproof sanding paper. The surface can now be treated with hydrochloric acid, ammonia or any other agent of your choice. This accelerates the rusting process. When the desired effect is achieved, the process can be stopped by using water and soda. To make sure the effect is maintained, a sealer can be applied. If the sealer is not applied, the process will continue as it would do naturally. In the same way you can achieve a bronze effect by adding an equal amount of bronze power.
HOW MUCH ACRYLIC ONE DO I NEED?
We use the following calculation. When applying 1 layer of Acrylic One of 1 mm thickness you will use 1.75kg Acrylic One per m2.
In a mould you normally work with a first layer of 2 mm. Next we advise you to use 3 layers of Triaxial fibre. In order to achieve this you will have to apply 4 layers of Acrylic One of 1 mm. Normally in a mould we thicken Acrylic One for the first layer (Gel coat) with Thix A. Make sure this layer is hardened before applying the next layers, and use one layer of Acrylic One between your hardened first layer and the first layer of Triaxial fibre in order to make a proper bonding.
Example: needed for a project of 5 m2
- 2 mm 1st layer
- 4 layers of 1 mm Acrylic One in order to apply the 3 layers of Triaxial fibre
Total 6 mm Acrylic One multiplied by 1.75kg multiplied by 5m2=52.5kg Acrylic One (=17.5kg Liquid and 35kg Powder)
Be aware that this is an indication and not a general rule.
For 1 litre of Acrylic One you will need 1.75kg of Acrylic One material.
For smoother surfaces
Using a sponge is an excellent and easy method for getting a smoother surface after laminating. For the best result:
only use a little water (moist not wet!). Too much water will make the layer of Acrylic One weaker
start using the sponge at the moment the curing of Acrylic One starts. After an hour the Acrylic One will become too hard to use a sponge and other sanding materials are advised
be gentle at the beginning of the curing process
Light spots or colour variations after demoulding
If you appear some light spots, colour difference or "water marks" in your product it might help to have a early demoulding. Due water evaporation this can happen. In some cases, for example when using wood or foam or laminate a thick layer, the water cannot leave the product easy on the surface side. A fast demoulding gives you also the opportunity to have several, up to 8, demouldings a day
Painting Acrylic One Objects
Acrylic One can easily be painted afterwards and for indoor use we see little problems. However for outdoor use not all paint systems seem to hold well over longer periods, which sometimes may cause problems. That's why you are advised to do your own testing before you decided to sell your Acrylic One object commercially. Because there are so many different kind of paint systems it is impossible to give individual advice. However Acrylic One can recommend TRIMETAL PERMACRYL from Akzo Nobel as a paint system that works very well on Acrylic One and has proven itself over longer periods in outdoor use.
Acrylic One objects need to be completely dry before being painted. Acrylic One advises a minimum of five days drying at room temperature.
Acrylic One for wet applications
Acrylic One objects are NOT suited to be placed in permanent water (e.g. ponds or aquaria). Temporarily water, such as rainwater, is not problem as long as the Acrylic Object has the chance to dry and is coated with a sealer.
Acrylic One and food
Acrylic One is not suitable for food and drinks