PRODUCT DATA SHEET Sika Cable System

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1 PRODUCT DATA SHEET Corrosion protection for bridge cables of steel and galvanized steel PRODUCT DESCRIPTION The Sika Cable System consists of coating materials as well as a sealing respectively injection materials. Suitable for coating or sealing of bridge cables and steel constructions exposed to vibration as well as deformation. Sika Cable FE Primer Sika Cable FE Primer is a 2-pack low solvent containing primer coat based on epoxy resin. It contains active corrosion pigments, is versatile overcoatable and adheres very well to steel. Sika Cable ZN Primer Sika Cable ZN Primer is a 2-pack low solvent containing primer coat based on epoxy resin. The product contains micaceous iron oxide, is versatile overcoatable, of high chemical and mechanical resistance and adheres very well to galvanized steel. Sika Cable TOP-1 Sika Cable TOP-1 is a 2-pack low solvent content intermediate coat of low solvent content, based on polyurethane. It contains micaceous iron oxide and is of high elasticity, impact strength, wear resistance and very good corrosion protection. Sika Cable TOP-1 is high-build applicable and very fast curing. Sika Cable TOP-2 Sika Cable TOP-2 is a 2-pack low solvent content, flexible, lightfast and weather resistant polyurethane top coating. Low solvent content referring to Protective Coatings Directive of German Paint Industry Association (VdL-RL 04). Sika Cable Flex-1 Sika Cable Flex-1 is a flexible, total solid 2-pack sealer based on polyurethane. Because of its high flexibility and expansion ability it is especially suitable for filling joints and gaps exposed to vibration (e.g. anchoring of bridge cables). 1/5

2 PRODUCT DESCRIPTION (Continuation) USES PROPERTIES Sika Cable Flex-2 Sika Cable Flex-2 is a total solid, flexible injection resin of low viscosity based on polyurethane for filling hollow spaces, (e.g. in parallel cables) and has a high penetration ability. Solvent free referring to Protective Coatings Directive of German Paint Industry Association (VdL-RL 04). Flexible and high-build corrosion protection for bridge cables of steel and galvanized steel. - Very good corrosion protection characteristics - Flexible, even at low temperatures - High weather and colour resistance TESTS PRODUCT DATA APPROVAL / STANDARDS The system was tested and listed according to ZTV-KOR Cables (German Guideline). COLOUR SHADES Sika Cable FE Primer: Red brown, sand yellow Sika Cable ZN Primer: DB 703 Sika Cable TOP-1: DB 703, DB 601 Sika Cable TOP-2: RAL- and DB-colour shades upon request Sika Cable Flex-1: Grey Sika Cable Flex-2: Beige Because of the raw materials used, slight batch to colour variations are unavoidable. PACKAGING Sika Cable FE Primer: 15 kg net. Sika Cable ZN Primer: 15 kg net. Sika Cable TOP-1: 3 kg net. Sika Cable TOP-2: 3 kg net. Sika Cable Flex-1: 2.5 litres Sika Cable Flex-2: 12.5 kg net. Sika Thinner EG: 25, 10 and 3 litres SHELF LIFE SYSTEMS COATING SYSTEMS In originally sealed containers in a cool and dry environment: Sika Cable FE and Sika Cable ZN Primer: Sika Cable TOP-2: Sika Cable TOP-1, Sika Cable Flex-1, Sika Cable Flex-2: 3 years 2 years 1 year Steel: 1-2 x Sika Cable FE Primer, 50 microns NDFT per layer 2-3 x Sika Cable TOP-1, 150 microns NDFT per layer 1 x Sika Cable TOP-2, 60 microns NDFT Galvanized steel: 1 x Sika Cable ZN Primer, 50 microns NDFT 2-3 x Sika Cable TOP-1, 150 microns NDFT per layer 1 x Sika Cable TOP-2, 60 microns NDFT When overcoating Sika Cable TOP-2 the existing surface must be mechanically prepared. Sika Cable Flex-1 and Sika Cable Flex-2 are applied directly on to the Sika Cable FE Primer respectivly Sika Cable ZN Primer. 2/5

3 SURFACE PREPARATION Steel: Blast cleaned to Sa 2 ½ according to EN ISO 12944, part 4. Free from dirt, oil and grease. Galvanized steel: Free from oil, grease and corrosion products. Surface preparation according to ZTV-ING, part 4, section 5 Corrosion protection of cables and ropes. TECHNICAL DATA MATERIAL CONSUMPTION Product Specific gravity liquid Solids content % Theoretical material-consumption/voc without loss for medium dry film thickness kg/l by vol. by weight dry microns wet microns kg/m² VOC g/m² Sika Cable FE Primer Sika Cable ZN Primer Sika Cable TOP Sika Cable TOP Sika Cable Flex-1 and Sika Cable Flex-2: specific gravity: 1.2 kg/l consumption: 1.2 kg per 1000 cm³ volume to be filled MIXING RATIO AND APPLICATION TIME (20 C): Product Mixing proportion in parts by weight Application time at 20 C Sika Cable FE Primer 90 : 10 8 h Sika Cable ZN Primer 90 : 10 8 h Sika Cable TOP-1 85 : 15 1 ½ h Sika Cable TOP-2 83 : 17 2 h Sika Cable Flex-1 3,5 : 1 1 h Sika Cable Flex : 20 2 ½ h RESISTANCE HINTS OF APPLICATION PREPARATION OF MATERIAL The Sika Cable System is resistant to weathering, water, de-icing salts, oils and grease. Coating materials: Stir Component A very thoroughly using an electric stirrer. Add component B and mix both components very thoroughly (including sides and bottom of the container). Sika Cable Flex-1 and Sika Cable Flex-2: Stir component A slowly by means of an electric stirrer (max. 300 rpm), subsequently add hardener in the correct mixing proportion and mix intensively again using an electric stirrer ( rpm) until a homogeneous mixture is achieved (min. 3 minutes). Take care that no air is entrapped. 3/5

4 APPLICATION METHOD Coating materials: The method of application has a major effect on achieving uniform thickness and appearance. Adding solvents reduces the sag resistance and the dry film thickness. In case of application by roller or brush, additional applications may become necessary to achieve the required coating thickness, depending on type of construction, site conditions, colour shade etc. Prior to major coating operations a test application on site may be useful to ensure the selected application method will provide the requested results. APPLICATION CONDITIONS DRYING STAGE 6 (EN ISO ) By brush and roller: According to ZTV-KOR Cables brushing is the preferred application method. Where light and intense colour shades are applied, a second top coat might become necessary. Sika Cable Flex-1 and Sika Cable Flex-2: The application technique depends on the design features of the project. Steel has to be primed with Sika Cable FE Primer, galvanized steel with Sika Cable ZN Primer. DO NOT THIN Sika Cable Flex-1 and Sika Cable Flex-2. Min. + 5 C (material and surface) Relative humidity: Max. 85 %, except the surface temperature is significantly higher than the dew point temperature, it shall be at least 3 K above dew point. If necessary max. 5% Sika Thinner EG may be added to adapt the viscosity. Product Dry film thickness + 10 C + 20 C + 30 C Sika Cable FE Primer 50 μm 10 h 3 ½ h 2 h Sika Cable ZN Primer 50 μm 12 h 6 h 6 h Sika Cable TOP μm 20 h 20 h 15 h Sika Cable TOP-2 60 μm 15 h 6 h 4 h SHORE-HARDNESS Product Shore hardness A Sika Cable Flex Sika Cable Flex WAITING TIME BETWEEN COATS Minimum 24 h at + 20 C FINAL DRYING TIME THINNER Depending on layer thickness and temperature final hardness is achieved within 1-2 weeks. Sika Thinner EG 4/5

5 2014 Sika Deutschland GmbH IMPORTANT NOTICE EU-DIRECTIVE 2004/42/EC (DECOPAINT) VALUE BASE LOCAL RESTRICTIONS HEALTH AND SAFETY INFORMATION LEGAL NOTES For product category IIA / j, Type Sb, the maximum permissible content of VOC according to the EU-Directive 2004/42/EC is 500 g/litre (limit 2010). The maximum VOC-value of Sika Cable System is below 500 g/litre. All technical data stated in this are based on laboratory tests. Actual measured data may vary due to circumstances beyond our control. Please note that as a result of specific local regulations the performance of this product may vary from country to country. Please consult the local for the exact description of the application fields. Skin contact with epoxy resins can lead to allergies! Avoid direct skin contact at all costs when handling epoxy resins! For the selection of suitable protective equipment, we have made our information data sheets 7510 General notes on occupational safety and 7511 General notes for wearing protective gloves available at In conjunction with this we also recommend the BG Bau service pages for information regarding the handling of epoxy resins ( Information on the safe handling of chemical products, as well as the essential physical, safety-related, toxicological and ecological data can be found in the current safety data sheets. Observe all relevant regulations, e.g. the hazardous substances act. Further notes and information data sheets on product safety and disposal can be found on the Internet at The information, and, in particular, the recommendations relating to the application and enduse of Sika products, are given in good faith based on Sika s current knowledge and experience of the products when properly stored, handled and applied under normal conditions in accordance with Sika s recommendations. In practice, the differences in materials, substrates and actual site conditions are such that no warranty in respect of merchantability or of fitness for a particular purpose, nor any liability arising out of any legal relationship whatsoever, can be inferred either from this information, or from any written recommendations, or from any other advice offered. The user of the product must test the product s suitability for the intended application and purpose. Sika reserves the right to change the properties of its products. The proprietary rights of third parties must be observed. All orders are accepted subject to our current terms of sale and delivery. The most recent product data sheet applies. This can be requested from us or is available to download at Please check availability of local product data sheet at your local website. In cases of doubt the German text is valid. Sika Deutschland GmbH Industrial Coatings Rieter Tal Vaihingen / Enz Germany Version given by Industrial Coatings Phone: (07042) Fax: (07042) Mail: 5/5

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