PACKING

CAPSTONE™ is available in two different sizes. For larger repairs, the 5 kg unit (4 units per case) is recommended. For smaller repairs, use the 2.5 Kg unit (also 4 units per case).

STORAGE

Store the CAPSTONE™ material in a dry, heated environment off the floor. DO NOT allow to freeze. Shelf life is two years.

TOOLS REQUIRED

The following tools are required for the preparation and application of the CAPSTONE™ Repair Material: chisel (hand); hammer; heat gun (Master Heat Gun HG501A or equal will heat spreader 51024); wirebrush; stir stick; surface thermometer (300ºF); trowels (square head); paint brush (1"); safety goggles; rubber gloves.

PREPARATION OF REPAIR AREA

To reduce the time of repair, care should be taken to maintain the pulpstone temperature as high as possible. Upon shutdown of the grinder, ensure that no water is allowed to contact the pulpstone surface. The repair area must be kept completely dry. The damaged area of the pulpstone should be inspected for any loose or defective material and should be hand chiselled and wire brushed clean. Avoid disturbing any adjacent segments or anchor bolts.

Do as little chiselling and removal of abrasive material as possible. Do not use pneumatic or electric chisels. The repair should be wire brushed and cleaned with air until the area is free of loose dirt or pulp, then heated and dried with a heat gun. Do not use an open flame such as an acetylene torch to heat or dry the stone.

MIXING AND APPLICATION OF PRIMER

The CAPSTONE™ Repair Material is supplied as a two-part Primer and two-part Mortar system. Mixing procedures for the Primer are as follows: Add component "B" to "A" and stir thoroughly with the stir stick. Pre-heat the repair area to 150ºF (65ºC), checking the temperature with the surface thermometer.

Do not allow repair area surface to exceed 180ºF (82ºC) before applying Primer. Apply very liberal amounts of the Primer to the entire repair area using the paint brush. Re-apply heat for a short duration until the Primer becomes tacky. If the Primer is allowed to harden completely, "roughing" and "re-priming" is recommended.

MIXING AND APPLICATION OF MORTAR

Add component "B" to component "A" (the mortar) in the pail. Mix by hand until thoroughly blended (rubber gloves required). If the mortar is not completely mixed, soft spots will occur in the repair. Place the mixed CAPSTONE™ Mortar into the repair area and level with a trowel even with the stone surface, packing the mortar solidly into all corners.

If the PULPSTONE surface temperature is 150ºF (65ºC) or higher, the patching compound can be applied in a full depth layer and then heated for 30-45 minutes with a heat gun set to 350ºF (177ºC). Should too much heat be applied, the mortar will begin to bubble. If the surface temperature is below 150ºC (65ºC), apply the mortar in one-inch layers and heat each layer at 300ºF (150ºC) until it begin to generate its own internal heat.

Apply the subsequent layers following the same heating procedure for each one-inch layer.

NOTE: If the CAPSTONE™ Mortar is allowed to harden completely between application of layers, re-priming is recommended.

EDGE REPAIR

In addition to the above instructions, should an edge segment require repair, the following is recommended: a form should be cut from wood to conform to the Pulpstone curvature and covered with polyethylene. The mortar can then be filled between the form and the stone, and heated. Immediately prior to the CAPSTONE™ hardening, remove the form and heat the edge of the repair until hard.