REPAIRING YOUR PLEXICOR PRODUCT

A - Deep scratches, chips and deep burn marks

1. Repair kits

Repair kits are intended to be used to repair the above damage on all Plexicor products. Repair kits are not intended to repair structural damage to the fibreglass reinforcement backing or acrylic surface.

Repair kits are supplied in two parts: a mobile syrup, (component A) and a liquid catalyst (component B). The component A is pigmented to approximately match the given product colour. The colour of the product must be specified when ordering the repair kit. The syrup is cured by addition of the catalyst. The syrup consists of a solution of acrylic polymer additives, in acrylic monomer. Cure is effected by polymerization of this monomer. The repair material is therefore of the same type of acrylic material as the product itself, and has similar properties.

2. Preparation of the syrup

The component A syrup must first be very well mixed in order to homogeneously re-disperse the pigments. These tend to settle out on standing. Failure to adequately mix the pigments will result in an off colour or semi-transparent repaired area.

One part (either by mass or by volume) of component B catalyst is then added to 25 parts of component A syrup, and the mixture is stirred thoroughly so that the catalyst is evenly dispersed. The mixture is then left for air bubbles, entrained during mixing, to rise to the surface. The bubbles may preferably be evacuated using a vacuum chamber. The syrup is then ready for use. The syrup must be used within 20 minutes of catalyst addition, or cure will be too advanced to give an effective bond to repair the site. Cure rate is dependent on ambient temperature, and repairs should not be attempted below an ambient temperature of approximately 20 degrees Celsius.

3. Repairs

A good bond may not be obtained unless the repair site is clean, dry, and free of contaminants. A light sanding of the repair area is preferable. The gap filling properties of the syrup are limited due to it's viscosity, and masking or syrup retaining techniques are required to retain the syrup in place during cure. Cure is accompanied by a reduction in volume of circa 20%, and therefore when a cavity is being filled with syrup, excess must be added to counteract this contraction.

The syrup will be touch dry within a few hours, depending on temperature. No heating is required. It is best left overnight to fully cure, after which the excess material may be sanded down with 1200 grit water paper (400 grit in the case of kitchen sinks) to the level of the original surface, then polished to a matching high gloss, using polishing compound such as Brasso. No polishing is necessary in the case of kitchen sinks as the repair will restore the matt finish.

Note that due to small variations of pigment shade, and small changes in colour of the original product in service, the repair colour may not be anything other than an approximation to the product colour, and not an exact match. This is unavoidable. In certain shades, there may also be slight yellowing of the repaired area with time, compared to the product colour. This is especially the case where excess catalyst is needed.

4. Safety warning

Repair kit is flammable, and the acrylic monomer in the syrup has a flash point of 11C. The syrup should not be exposed to naked flames. Concentrations of acrylic monomer of between 2.1% by volume in air at 25C form vapour mixtures, which may be explosive if ignited.

The vapour is heavier than air and continuous breathing of small quantities may have a cumulative toxic effect. The area of use should therefore be well ventilated. Occupational Exposure Limit (OEL) for an 8 hr TWA for acrylic monomer is 100ppm.

...................................................................................................................................................................................................

B. Light scratches and cigarette burns

Sanitaryware

It is possible to remove light scratches and minor cigarette burns by polishing them out with 1200 grit waterpaper and finishing them off with Brasso or other polishing compound to bring up the natural gloss.

Kitchen sinks

Light scratches and cigarette burns can be removed by sanding them off the Karran matt surface with not more than 400 grit waterpaper. If a finer grain waterpaper (eg: 500 grit) is used, it will make the surface shiny.