5. Mixing Matrix Premium Resin, Matrix Topcoat and Catalyst

General Information

Premium Resin and Premium Topcoat will require stirring before the addition of catalyst
Resin and Topcoat both require catalyst. Topcoat is not paint.
Without catalyst the laminate will not cure and will fail
It is essential to add the correct quantity of catalyst.
Too much catalyst weakens cured resin and topcoat.
Higher temperatures reduce pot life (gel time) and shorten cure time.
Lower temperatures increase pot life and lengthen cure time.
More catalyst reduces pot life and shortens cure time
Less catalyst increases pot life and lengthens cure time
Never add less than 1% catalyst and never add more than 4% catalyst
Ideally use Premium Resin and Topcoat between 15deg C and 25 deg C
Do not use Premium Resin and Topcoat below 10 deg C and above 30 deg C
Use Premium Zero Resin and Zero Topcoat between 0 deg C and 10 deg C
Catalyse Premium Zero Resin and Zero Topcoat at 2-3%
Keep resin and topcoat cool in summer and warmer in winter
600gm glass mat will require approx 1.8kg of resin
500gm of topcoat will approx cover 1m2
Observe shelf life and use-by dates printed on the containers.
Record batch numbers for the Guarantee paperwork.

Resin, topcoat and catalyst are sold by weight but catalyst is dispensed and added by volume! For our purposes the difference is not important and can be disregarded.
Assume that a 1L bucket of resin or topcoat weighs 1kg (or 5L = 5kg or 10L = 10kg) and use the following catalyst addition chart as a guide:

Gel times are approximate and will be affected by the temperature of the resins and the deck.

Premium Resin and Premium Topcoat will gel and cure much quicker in direct sunlight.
When top-coating late in the day add more catalyst to compensate for the lack of sunlight.
Winter and summer catalysts (fast and slow) can be used to accommodate seasonal conditions. Maintain catalyst percentages as shown in the chart.
Excess catalysed resin or topcoat will gel then ‘exotherm’ in the bucket. In larger quantities the exotherm with generate considerable heat and smoke and could catch fire.
Do not place hot buckets near other flammable materials.
Water can be poured over the resin to suppress the heat gain.
Catalysed resin or topcoat mixes kept is a small containers have shorter pot lives.
Larger containers with small mixes extend pot life.
Catalyst is dangerous and should be handled with extreme care (see Safety Data Sheets)
Always wear protective gloves, goggles and overalls when working with resins and catalysts
Always measure and dispense catalyst from a catalyst dispensing bottle
Do not allow catalyst to come into contact with skin or eyes
Always have a bottle of un-opened eyewash to hand.
Use sand or vermiculite to mop up spills. Do not use paper towels.
If in doubt seek medical attention

Use a square-ended flat stick or paddle to mix catalyst into resin and topcoat
It is essential to mix thoroughly. Mix 5kg of resin or topcoat for at least 60 seconds
If in doubt double-mix topcoat to ensure there are no un-catalysed residues in bucket
It is good practice to begin with a small quantity resin mix (1 or 2 litres) for details and bandaging. Small mixes will indicate and confirm if the correct amount of catalyst has been added to the mix
Start the main laminate with a 5kg mix.
When you are experienced mix larger quantities of resin - 10kg or even 20kg
Mix smaller quantities of topcoat
Do not mix more resin or topcoat than you can easily use within its pot-life
Generally It is practical to aim at a gel time of around 20 to 30 minutes