Basecrete is easy to mix and only requires common tools that you can find at a local hardware store and are not expensive.

The list of tools includes:

– Mortar mixer
– Buckets (at least two): one for mixing and one for water
– Steel smoothing trowel, rounded
– Plastic smoothing trowel
– Brushes (for detailed work and hard-to-reach areas)
– Water for cleaning tools and for wetting the entire application area
– Protective covers (tape, plastic, tarps, etc.)
– Gloves and personal protective equipment (PPE)
– Basecrete Fibermesh to reinforce tension areas (cracks) in two different materials.

– Metal trowel and plastic trowel
– Brush
– Paint roller; thick nap ¾ inch – ¼ inch
– Marshalltown rubber squeegee
– Floor rubber squeegee
– Hopper gun

A properly prepared substrate can mean the difference between a successful and a failed application. Proper substrate preparation ensures that Basecrete adheres to the substrate as planned.

Concrete substrates must be clean and free of dust and debris according to ASTM standards.

The concrete substrate must be SSD – Saturated Surface Dry. This is an industry term describing concrete that is wet but has no standing water.

This is what is required for a good application of Basecrete.

There are two key reasons for this:

1. Lowering the thermal temperature of the concrete if it is exposed to the sun. Applying Basecrete to a very hot substrate will cause it to dry quickly before it has the chance to adhere to the substrate.

2. The moisture within the concrete will attract the cement in the Basecrete compound, leading to a better bond between Basecrete and the substrate.

NOTE: All porous substrates must be wetted as indicated before applying Basecrete. Examples include plaster finishes, natural stones, CMU blocks, gunite, and shotcrete, etc.

For non porous substrates, care must be taken to ensure that there are no oils or other agents that could inhibit adhesion. Stainless steel, for example, often comes with an oil coating that must be removed before applying Basecrete. It can be easily cleaned with a cloth.

In the end, it simply comes down to common sense. We seek a clean, debris-free substrate with an ambient temperature of no more than 30°C (86°F).

Basecrete is mixed on-site immediately before use.

Before moving on to the actual mixing, it’s important to understand some key concepts about Basecrete.

Basecrete is a polymer-modified cement mix and, as such, it sets quickly.

Heat ACCELERATES the setting/curing of Basecrete.

Cold DELAYS the setting/curing of Basecrete.

The first rule of mixing when it comes to Basecrete is that we mix to a consistency, not a ratio. We mix Basecrete to the consistency of a vanilla milkshake, meaning thicker than water but still liquid.

This is an especially important concept because, for example, an applicator working in the summer at temperatures above 30°C will have a very different mixing ratio than an applicator working in the winter at an ambient temperature of 15°C or below. Similarly, an applicator working in a high-altitude city will have a different ratio than one working at sea level.

Therefore, to avoid this, Basecrete is mixed to a consistency rather than an exact ratio.

However, it is obvious that we start with some indicative measurements.

Consequently, the official instructions for mixing Basecrete waterproofing are:

1. Divide the contents of your 18 L bucket of liquid component (resin) into three equal parts, i.e., 6 liters each part.
– You can use a scale to weigh the liquid (resin) or use an empty 6 L jug and fill it with the liquid component to ensure you have the correct measure.

2. Take the bucket designated for mixing and add the 6 L of liquid component (resin) and add two parts of 1 bag of our special cement and mix well with the mortar mixer.
– Mix for 2 to 3 minutes until all lumps disappear and the mixture is homogeneous.

3. At this point, the mixture should have a very liquid gray color, basically like gray water. Or white if you are using white cement.

4. Continue adding the remaining bag of cement until you achieve a consistency thicker than water but still liquid.

5. Let it set for 3 to 4 minutes and then mix again well for an additional 45 seconds.
– Apply immediately after mixing.
– NOTE: In higher temperatures, it may be necessary to add a little more liquid to the mix before remixing.

However, the optimal ambient temperature for the application of Basecrete ranges between 15°C and 25°C (59°F to 77°F).

In summary, the two key points to remember are:

1. Basecrete is mixed to a consistency (not a ratio).
2. Allow the mixture to false set for 3 – 4 minutes.

*IMPORTANT NOTE:

I want to take a moment to explain the reason for the false setting step.

This is an important step in the application process that should not be overlooked. When the liquid and dry components of Basecrete are first mixed, a chemical reaction occurs. Molecules and atoms come together and bond. By breaking this chemical reaction, you force it to restart, and when it does, you achieve a final result that is stronger than if the reaction had not been broken. It’s a concept similar to when a bone is broken, the bone re-bonds and becomes stronger. Likewise, by forcing the molecules and atoms to readjust, you get a final Basecrete mix that is 20% stronger than if it had not been broken.

In the previous section, we discussed how to mix Basecrete to achieve a vanilla milkshake consistency, thicker than water but still liquid.

This is what we also call a “wet mix.” It is the most common way to prepare and use Basecrete. However, there is another way to prepare Basecrete for certain applications, which we call “dry mix preparation.”

A dry mix is simply a wet mix to which more compound has been added to create a consistency similar to mortar (instead of the liquid consistency). There are two levels of dry mix, primarily used for applications involving patching and concrete repair.

When creating your wet mix, you’ll achieve a ratio of approximately 2.5 to 3 parts compound to one part liquid. Here we are increasing that to a ratio of 4 to 1 and even 5 to 1 in certain circumstances.

This is what we would call a mortar mix. Use a mortar mix to repair profiles, cracks in concrete slabs, and spalling in concrete.

These are applications where the thickness of the Basecrete application is from 0.5 inches up to two inches.

Then, there are applications that require even more material. We are talking about applications that require even higher volumes of material. While we generally think of Basecrete as a coating, used to cover and seal concrete structures, in certain applications, we can use Basecrete as a concrete repair mortar. We are talking about applications such as deep concrete spalls and deep patch repairs.

Keep in mind that in these applications where Basecrete is used to fill voids or to build up levels, you might consider adding a volume filler to the Basecrete mix, such as pea gravel. You can add up to one-third of the volume of pea gravel.

The purpose of this section is to provide applicators with a few useful tips and tricks we’ve learned over the years.

Extending the Working Life

As mentioned before, polymer-modified cement hardens quickly, and this accelerates in hot weather.

Agitate your mix during application: Depending on the application method, if you can agitate your mix within your bucket, it will stay «loose» for longer.

For instance, if each time you dip your paint roller into the bucket, you dip it to the bottom once or twice, you’ll notice an improvement in the working life.

Re-mix a “hardened mix”: Maybe you had to take a call, and your mix has hardened while your attention was diverted. Simply re-mix the entire batch with the paddle mixer, and it will return
to a liquid state. You might need to add a splash of the liquid component as well. Use Basecrete liquid to adjust the fluidity (NEVER WATER).


Avoid the Temptation to “Finish the Bucket”

Trying to apply Basecrete that has partially hardened or cured beyond the point where it is no longer truly liquid can yield mixed results.

It’s better to add a bit of liquid and re-mix, or simply send the bucket back to the mixing station and get a fresh batch. This is a sign of a well-organized application.


Teams of Three People
On jobs with multiple people involved, it is highly recommended to designate one person as responsible for mixing. This person would ensure that the applicators always have a fresh supply of material ready to use. On larger jobs, where the rate of material consumption is higher, you may need to designate two or even three people as responsible for mixing.

The point here is that by separating the responsibility of mixing and applying, you have a better chance of consistently mixing throughout the job.

A well-organized mixing station will know when the applicators are running low on material so they can prepare the material, and they should always have a mix that is just a stir away from being ready to apply.


Extremely Hot Applications

Applications with ambient temperatures of 35°C or higher can be challenging due to the extreme heat, not just for the applicators but also for the material.

We’ve had cases where applicators were doing Basecrete applications in effective temperatures of 45°C or higher. These are extreme situations for applying Basecrete, and certain steps should be taken to ensure the proper consistency of the material.

Use of a retarder: Small amounts of concrete retarder can be added to the mix. We’re talking about a dose of one ounce of retarder for an 18 LT bucket mix. This will make the consistency looser, so use it carefully.

Keep the Basecrete liquid cool: If you can chill the Basecrete liquid when working in extreme temperatures, you will also notice an improvement in the product’s working life. This is not always practical, but some applicators will have a large ice tub where they keep the buckets until ready to use.

In these high-temperature applications, there is a tendency for applicators to try to make the liquid too watery to extend the working life, starting with a very loose mix. The problem with this approach is that you will end up using much more liquid, which, as we know, is the most expensive part of the two-component system.


Extremely Cold Applications
Just as extreme heat poses application challenges, so does extreme cold. As discussed earlier, cold temperatures prolong curing time.

A cold, humid environment without direct sunlight and no air movement can take 24 or even 48 hours or more to cure sufficiently to add a second coat.

In your cold weather applications, it is absolutely crucial to ensure that the first layer of your materials is sufficiently cured to receive the second coat.

There are very few things that can cause Basecrete to delaminate, but applying a second coat of Basecrete to a first coat that is not sufficiently cured is one of them.

Ways to accelerate the curing of Basecrete in the cold include introducing air movement to the area and, of course, trying to warm the area. But simply putting a fan in a closed room will speed up curing.


Application of the First Layer on a Slippery Surface, e.g., Stainless Steel, Tiles
When applying the first layer of Basecrete on a slippery surface, such as stainless steel, tiles, or a hopper gun, it is recommended to properly clean the surface to remove any residue or oil film that might interfere with adhesion and apply with a hopper gun to ensure better grip.

Often, I get asked what the best way to apply Basecrete is. The answer depends on the desired final finish. Just as there are a wide variety of applications you can do with Basecrete, there are also many ways to apply Basecrete.

The goal of this segment is to provide an overview of the most common application methods and tools used to apply Basecrete.

Before deciding which method to use for applying Basecrete, you need to know the type of finish required. Are you applying a final finish that needs to be smooth? Or are you applying a bonding layer that will be covered by another material and therefore needs a rough finish? Both applications can be done with Basecrete, but you would use very different tools for each application.

Paint Roller – Rough Finish

Thick Nap (¾ inch): For a CSP of 6-9.
– Example: For pool coatings or knockdown finishes.

Thick Nap (¼ inch): For a CSP of 3-5.
– Example: For tile or glass mosaic applications.

Rough finish applications are typically those where Basecrete will be covered by another material, such as pool coatings or stucco. It could even be another layer of mortar or concrete. In all cases, the advantage of having a rough surface is that it provides a greater surface area to bond the two materials. Some materials also shrink as they cure and grip firmly to those ridges in the rough finish.

Thinset mortar used to adhere tiles and mosaics is a good example of a rough finish that requires smaller ridges and valleys or a lower CSP of 3-5.

Trowel – Smooth Finish (Knockdown Finish)
Trowel applications are usually smooth. You would also use a trowel for your crack repair applications, as well as other general concrete repair applications. Basically, a trowel is always handy to have when applying Basecrete.

Squeegee – Smooth Finish
Squeegees and magic trowels (brand names) are ideal for large, horizontal applications. In fact, with the ease and speed at which you can apply large quantities of Basecrete, you’ll need to ensure that the supply of freshly mixed Basecrete can keep up with the demand.

Parking lots, industrial roofs, warehouse floors, factory floors, terraces, walkways, and more require waterproof coatings, and Basecrete is a great product to apply in these applications quickly and efficiently.

Basecrete is inherently non-slip, even when wet. However, it might be desirable to add some lines or sand to the material for additional slip resistance. This is extremely easy to do on your freshly squeegeed Basecrete surface using one of the following techniques:

Rolling a texture roller over the freshly placed Basecrete.
Sprinkling sand or quartz onto the Basecrete while it’s still wet.
Making lines with a broom on the wet Basecrete.
Knockdown effect.


Hopper Gun – Generally Smooth Finishes
Hopper guns are ideal in situations where the substrate you want to cover with Basecrete is highly irregular. Examples of such applications could be natural rocks, large stones, or severely damaged concrete. Basically, the hopper gun can follow the exact contours of your object or substrate. You can cover the object without changing its shape with a hopper gun.

A hopper gun is a good tool to get a scratch coat of Basecrete over materials where it might be difficult to make Basecrete «grab.»

For example, we’ve mentioned that Basecrete has amazing adhesion capabilities on materials like stainless steel or tiles. That’s true, but it can be a bit challenging to make the first coat stick, as it will simply slide over a material like stainless steel. If you’ve ever tried to roll Basecrete over a piece of stainless steel, you’ll know what I mean.

With a hopper gun, you can spray a very thin «scratch» coat over this «slippery» substrate quickly and easily. Additionally, since you’re spraying an extremely thin layer, it will dry very quickly, allowing you to start the true Basecrete application with your roller or trowel. You’ll no longer have the problem of the material «sliding» over the substrate.

Basecrete Curing Times: Importance and Key Considerations

Questions about curing times arise frequently. There are some particularly important considerations here, making this an essential topic to master. Not respecting curing times during application can have disastrous effects in the future. In summary: learn this section and respect curing times.

When it comes to Basecrete and curing times, there are two main considerations:

1. Curing time between layers of Basecrete.
2. Curing time before covering Basecrete with another material or submerging it in water.


Curing Between Layers of Basecrete

Determining if your first layer of Basecrete is dry enough to apply the second layer on top is vital for the success of your application. Applying the second layer of Basecrete on top of the first layer before it has fully cured can lead to the delamination of the second layer in the future. This is obviously disastrous, so knowing when to apply the second layer is key.

Fortunately, this is quite easy to establish with a tool most of us already possess: **the thumbnail test**. Yes, your thumbnail is all the equipment you’ll need to determine if the first layer is dry enough to receive the second layer.

If you CANNOT mark the first layer of Basecrete with your thumbnail, then your Basecrete is ready for the second layer application. It’s that simple.

The fact that we are dedicating an entire module to this topic shows the importance we place on it. You should do the same.

The reason we mention this is that the time between two layers of Basecrete can vary greatly depending on temperature. Remember that heat accelerates curing, while cold slows it down significantly. For example:

On a hot day outdoors in Miami, Florida, with temperatures of 30 degrees Celsius, the curing time can be as short as 60 minutes.
In contrast, working in a basement in Michigan, with an ambient temperature of 15 degrees Celsius, cold and humidity, that same layer of Basecrete may take up to 48 hours to cure enough for the second layer.

Curing Before Submerging or Covering

The second aspect of curing times is knowing when Basecrete can be submerged in water or have another material added on top of it. This process is less complicated to determine.

The thumbnail test concept remains valid here for colder climates, but the rules are clearer. In summary, simply wait a **minimum of 24 hours** before proceeding. You may need to wait longer if the thumbnail test shows more curing is required, but never less than 24 hours.


Reinforced with Mesh: Basecrete Fibermesh

Basecrete offers a fiber mesh that can be used to reinforce Basecrete. You can think of Basecrete Fibermesh as the «rebar» for Basecrete.

Basecrete Fibermesh is a standard 4.5 oz fiberglass reinforcing mesh made of interlaced fiberglass threads. The fibers are coated with resin polymers to enhance their resistance to attack by the alkalinity of Portland cement-containing mixtures.

Reinforcing Basecrete with Fibermesh allows for greater mobility within the material and provides greater stress resistance.

Main Applications of Basecrete Fibermesh

1. Crack Repair
Cracks usually form as a result of stress on the concrete caused by movement or settling. To prevent new cracks from forming in repaired areas, it is essential to reinforce these areas with Fibermesh.

2. Joining Two Different Materials
Adhering a material to two different substrates can be tricky, as these materials expand and contract at different rates. Using Fibermesh in these areas helps manage the stress and movement, improving the durability of the bond.

3. Cold Joint Between Vertical and Horizontal Planes (Corner of Wall and Floor)
A cold joint is never waterproof by itself and always requires waterproofing. This is common in suspended pool construction, where the pool floor would be poured, and later the walls would be poured vertically over the existing floor slab. Reinforcing these areas with Basecrete Fibermesh helps manage the stress induced by the water load and prevents waterproofing issues.

In summary, both curing time and the proper use of reinforcements like Basecrete Fibermesh are crucial to ensuring a successful and durable application of Basecrete.