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C, 3.1. Prepare a work area that is clean, dry and well -ventilated, either naturally or mechanically. Working with materials in di- rect sunlight may accelerate the cure time. Therefore, be sure the work area is not in direct sunlight. 3.2. Take a piece of plywood or a similar flat surface to work on and cover it with a large piece of cardboard. 3.3. Arrange materials within easy reach of this work area. WARNING Keep materials away from all flames, sparks or other heat sources. Smoking is prohibited within 50 feet of the work area. Failure to follow this warning could result in death or serious injury. 4. PREPARING THE RESIN -CATALYST MIXTURE 4.1. Mix the resin and catalyst according to the minimum and maximum proportions given in TABLE 4-1. The amount of cat- alyst noted in this table may be adjusted with temperature variations: higher temperatures may call for slightly less cata- lyst and lower temperatures may call for slightly more catalyst. An improper proportion of resin to catalyst may keep the lami- nate from setting up properly. TABLE 4-1 4.2. Xerxes recommends that you begin by mixing one (1) pint of catalyzed resin at a time. You can increase this amount to up to one (1) quart as you become more familiar with the process. 4.3. Add the catalyst to the resin and mix thoroughly. 4.4. Continue to mix single batches of catalyzed resin as you do the lay-up work so you have the catalyzed resin needed to create the laminate. 4.4.1. You will need approximately 3/4 gallon of catalyzed resin per joint. 4.5. Each fresh batch of catalyzed resin will give you a working time of approximately 20 minutes. 5. LAMINATING A JOINT CAUTION Always wear rubber gloves and safety glasses when han- dling and working with fiberglass materials. Failure to do so may result in minor or moderate injury. 5.1. Sealing a joint requires six (6) laminates. Each laminate consists of four (4) pieces of 6 -inch by 28 -inch fiberglass mat (saturated with resin -catalyst mixture) placed on top of each other. 5.2. The six (6) laminates are to be placed centered on the joint with the following overlap as laminates are placed around the circumference of the sump: • 5.2.1. On a 42 -inch containment sump, each of the laminates should overlap the preceding laminate by 6 inches. The sixth laminate should also overlap the first laminate by 6 inches. 5.2.2. On a 48 -inch containment sump, each of the laminates should overlap the preceding laminate by 3 inches. The sixth laminate should also overlap the first laminate by 3 inches. 5.3. Each laminate should be prepared and then immediately applied before other laminates are made. NOTE: Do not prepare all laminates at the same time. Pre- pare and apply one at a time. 5.4. To create each laminate, follow these instructions: 5.4.1. Using the wet -out roller, apply a thin layer of catalyzed resin on the prepared cardboard work surface. 5.4.2. Place one (1) piece of 6 -inch by 28 -inch fiberglass mat on top of this resin. 5.4.3. Roll this fiberglass mat with resin until the fibers are sat- urated. Take care not to apply an excessive amount of resin. 5.4.4. Place a second piece of fiberglass mat on top of the first mat and roll it with resin as described in POINT 5.4.3. 5.4.5. Place a third piece of fiberglass mat on top of the sec- ond matt and roll it with resin as described in POINT 5.4.3. 5.4.6. Place a fourth piece of fiberglass mat on top of the third matt and roll it with resin as described in POINT 5.4.3. 5.4.7. This is a complete four -layer laminate. 5.5. Pick up the laminate and center it on the joint. 5.6. Taking care to keep the laminate in place and centered on the joint, smooth any protruding glass fibers with compacting roller. 5.7. Using the compacting roller, roll out the laminate to re- move all trapped air and to smooth all edges. When the lami- nate is properly smoothed, any white glass in the laminate should disappear and become one solid color. NOTE: No air pockets, wrinkles, burrs or protruding glass fibers should remain in the laminate. CAUTION Whenever necessary during the roll-out procedure, clean the roller and gloves with acetone to ensure that no resin has gelled or hardened on the tools. Failure to do this may cause the fiberglass seal to fail. 5.8. Create and apply each of the next five (5) laminates, one at a time, by repeating POINTS 5.4.1. through 5.4.6. 5.9. After placing the six (6) laminates around the joint, let the laminates cure until they are cool to the touch. This should take between 1/2 hour and 1 hour. 5.10. Once the laminates are cool, abrade them to remove any burrs. 5.11. Make sure all abraded areas are still adequately coated with resin. If they are not, apply resin -catalyst mixture to any exposed abraded surface of the joint. Then cure areas where you applied more resin -catalyst. 5.12. Xerxes recommends that you wait at least 4 hours before backfilling around the containment sump or exposing it to water after the final cure is complete. CAUTION Dispose of unused materials in accordance with all fed- eral, state and local safety regulations that may apply to these materials. DO NOT discard these materials with general trash and debris. XE RXE 5® a zcL company 7901 Xerxes Avenue South, Minneapolis, MN 55431-1288 a 952.887.1890 a www.xerxes.com 0 2012 ZCL Composites Inc. xFFL1Oil 2ih Resin -to -Catalyst Ratio Resin Catalyst in Catalyst in Catalyst in cool or overcast standard hot or sunny conditions conditions conditions 16 fl oz (1 pt) 6 ml 5 ml 4 ml 32 fl oz (1 qt) 12 ml 10 ml 8 ml 128 fl oz (1 gal) 48 ml 40 ml 32 ml TABLE 4-1 4.2. Xerxes recommends that you begin by mixing one (1) pint of catalyzed resin at a time. You can increase this amount to up to one (1) quart as you become more familiar with the process. 4.3. Add the catalyst to the resin and mix thoroughly. 4.4. Continue to mix single batches of catalyzed resin as you do the lay-up work so you have the catalyzed resin needed to create the laminate. 4.4.1. You will need approximately 3/4 gallon of catalyzed resin per joint. 4.5. Each fresh batch of catalyzed resin will give you a working time of approximately 20 minutes. 5. LAMINATING A JOINT CAUTION Always wear rubber gloves and safety glasses when han- dling and working with fiberglass materials. Failure to do so may result in minor or moderate injury. 5.1. Sealing a joint requires six (6) laminates. Each laminate consists of four (4) pieces of 6 -inch by 28 -inch fiberglass mat (saturated with resin -catalyst mixture) placed on top of each other. 5.2. The six (6) laminates are to be placed centered on the joint with the following overlap as laminates are placed around the circumference of the sump: • 5.2.1. On a 42 -inch containment sump, each of the laminates should overlap the preceding laminate by 6 inches. The sixth laminate should also overlap the first laminate by 6 inches. 5.2.2. On a 48 -inch containment sump, each of the laminates should overlap the preceding laminate by 3 inches. The sixth laminate should also overlap the first laminate by 3 inches. 5.3. Each laminate should be prepared and then immediately applied before other laminates are made. NOTE: Do not prepare all laminates at the same time. Pre- pare and apply one at a time. 5.4. To create each laminate, follow these instructions: 5.4.1. Using the wet -out roller, apply a thin layer of catalyzed resin on the prepared cardboard work surface. 5.4.2. Place one (1) piece of 6 -inch by 28 -inch fiberglass mat on top of this resin. 5.4.3. Roll this fiberglass mat with resin until the fibers are sat- urated. Take care not to apply an excessive amount of resin. 5.4.4. Place a second piece of fiberglass mat on top of the first mat and roll it with resin as described in POINT 5.4.3. 5.4.5. Place a third piece of fiberglass mat on top of the sec- ond matt and roll it with resin as described in POINT 5.4.3. 5.4.6. Place a fourth piece of fiberglass mat on top of the third matt and roll it with resin as described in POINT 5.4.3. 5.4.7. This is a complete four -layer laminate. 5.5. Pick up the laminate and center it on the joint. 5.6. Taking care to keep the laminate in place and centered on the joint, smooth any protruding glass fibers with compacting roller. 5.7. Using the compacting roller, roll out the laminate to re- move all trapped air and to smooth all edges. When the lami- nate is properly smoothed, any white glass in the laminate should disappear and become one solid color. NOTE: No air pockets, wrinkles, burrs or protruding glass fibers should remain in the laminate. CAUTION Whenever necessary during the roll-out procedure, clean the roller and gloves with acetone to ensure that no resin has gelled or hardened on the tools. Failure to do this may cause the fiberglass seal to fail. 5.8. Create and apply each of the next five (5) laminates, one at a time, by repeating POINTS 5.4.1. through 5.4.6. 5.9. After placing the six (6) laminates around the joint, let the laminates cure until they are cool to the touch. This should take between 1/2 hour and 1 hour. 5.10. Once the laminates are cool, abrade them to remove any burrs. 5.11. Make sure all abraded areas are still adequately coated with resin. If they are not, apply resin -catalyst mixture to any exposed abraded surface of the joint. Then cure areas where you applied more resin -catalyst. 5.12. Xerxes recommends that you wait at least 4 hours before backfilling around the containment sump or exposing it to water after the final cure is complete. CAUTION Dispose of unused materials in accordance with all fed- eral, state and local safety regulations that may apply to these materials. DO NOT discard these materials with general trash and debris. XE RXE 5® a zcL company 7901 Xerxes Avenue South, Minneapolis, MN 55431-1288 a 952.887.1890 a www.xerxes.com 0 2012 ZCL Composites Inc. xFFL1Oil 2ih