Sika Ergodur®-500 Pro

• Test report no. P 4636, KIWA Polymer-Institute according to ZTV-ING 6-1, Test and Installation specifications TL/TP-BEL-EP.
• Compatibility test according to ZTV-ING 6-1, no. P 11514-1a: Sika Ergodur-500 Pro with SikaShield Ergobit Pro.
• Compatibility test according to ZTV-ING 6-3, Sika Ergodur-500 Pro with Sikalastic-851 and Sikalastic-822

In accordance to ZTV-ING 6-1 and 6-3, the following application instruction manuals are available as a part of the waterproofing system:

• Sika Ergodur-500 Pro Primer with SikaShield Ergobit Pro welded bitumen sheets
• Sika Ergodur-500 Pro Primer with Sikalastic-851 (spray application)
• Sika Ergodur-500 Pro Primer with Sikalastic-822 (manual application)

Sika Ergodur-500 Pro is also included in the German Highway Research Institute (BASt) in their "List of certified materials and systems”.

Solvent-free epoxy resin 

18 months from date of production 

In undamaged, unopened, original sealed packaging in cool and dry conditions, not lower than + 8°C. The material must not be used if the resin component crystallizes i.e. due to inadequate storage or transport at low temperatures; as curing problems can occur. Such crystallization can be reversed by heating the material in a water bath at 60°C.

Components A + B mixed viscosity: approx. 850 mPas 

approx. 100% 

approx. 100% 

Sika Ergodur-500 Pro is resistant to water, de-icing salt solutions and mineral fuels and lubricants and many other substances that are aggressive to concrete. 

Naked flame test passed (simulation of welding operation with a 7-flame burner). 

Component A : Component B = 4 : 1 (parts by weight) 

By using 1000kg IBC-Containers the mixing ratio by weight must be guaranteed. This may be done by weight scale or by using mashine mixing.

Minimum + 8°C
Maximum + 45°C 

Maximum 85% 

During application and hardening, the substrate temperature must be min. +3°C above dew point.

               
Protect from condensation before, during and after application until cured.

Minimum + 8°C
Maximum + 40°C 

Concrete bridges:
Substrate moisture content according to ZTV-ING 6-1 and 6-3 “Hot air blower” or "Hairdryer” test. For other structures: < 4% moisture by weight (measured with a CM meter) if specific ZTV-ING requirement are not applicable.

Primer:

• approx. 300 - 500 g/m² of binder per application 

Levelling layer:

• approx. 1.9 kg/m² per mm layer thickness (Mixed in a ratio of 1 : 3 with suitable aggregate filler)

Consumption is dependent on the substrate (e.g. profile and porosity etc.).

The substrate must comply with the requirements of ZTV-ING 6-1 and 6-3; its preparation and condition are described in the section "Substrate preparation".

The adhesion of the Sika Ergodur-500 Pro on the cementitious substrates is formed by a mechanical connection over the surface profile (roughness) and a good penetration into the substrate.

                   
High strength concrete, vacuum formed surfaces and other extremely smooth and very dense concrete substrates need more intensive mechanical preparation.

                
After surface preparation the embedded aggregates in the concrete must still be visible. In some cases a sample area should be prepared. Therefore abrasive substrate preparation (e.g. blastcleaning) is always required.

                    
All concrete surfaces or concrete replacement / repair mortars to be coated must be sound, dry and free from any cement laitance, loose or friable particles, oils and grease, or any other dirt and contaminants.

Prepare the substrate by blastcleaning (grit or shot blasting), suitable mechanical scabbling / grinding / milling etc. This is also essential on PCC I mortars.

The average surface pull-off strength of the substrate must be minimum 1.5 N/mm². For the moisture content of concrete bridges the regulations of the ZTV ING are applicable.

On other engineering structures ensure that the concrete moisture content is less than 4% by weight (measured with a suitable CM meter).
 

Binder:
Sika Ergodur-500 Pro is supplied in 2 components (component A = resin and component B = hardener) pre-batched in the correct mixing ratio (except for bulk packaging which must be dosed on site).

               
Prior to application, thoroughly mix components A + B together in the specified mixing ratio. To prevent the liquid splashing or spilling from the mixing container, mix the components briefly with a continuously adjustable electric mixer at low speed.

Then slowly increase the speed to maximum 300 rpm to mix the materials thoroughly. The minimum mixing time is 3 minutes until a fully homogeneous mix is obtained. Decant the mixed material into a clean container and mix briefly again as described above.

2-component epoxy resins generate heat when reacting (exothermic reaction). After mixing both components together the material must not remain in the mixing container longer than the stated pot life and must be used immediately as stated in the application instructions, otherwise heat and smoke may develop and in extreme cases this could even cause a fire.

               
When using premixed sand/aggregate mixes only use the complete content of each bag as the aggregates tend to settle and separate during transport and storage.

Filling ratio for levelling - / surface filling mortar:
1 part by weight mixed Sika Ergodur-500 Pro:
+ 3-4 parts by weight aggregate (e.g. Sika Aggregate KR N); tested premixed aggregates in 25 kg bags) 

Hints on filling ratio:
The possible filling ratio of the Sika Ergodur-500 Pro depends on the temperature. The ratios given here refer to a material-, substrate- and ambient temperature of 20°C. Higher or lower temperatures will lead to a different filling ratio.

Mixing Equipment:

Sika Ergodur-500 Pro binder is mixed with an electric mixer at max. 300 rpm.

With Sika Thinner C