Armorgard 541
Thixotropic Foam Mold Coating

  • Solvent Free-Zero VOC
  • Extremely Tough, Non-brittle Surface
  • Single Coat Application
  • Seals Hotwire Cut Foam Patterns
  • Low heat on cure
  • Does not distort Mold Shape
  • Armorgard 541 is a 100 % solids, thixotropic, primerless, odorless epoxy coating for foam patterns and molds used in precast concrete applications. Armorgard 541 is formulated to provide a hard, tough coating for EPS foam and Styrofoam without the use of hazardous – foam damaging solvents. Use of Armorgard 541 transforms a “rough” foam structure into a hard, sandable surface, creating an “architectural” quality cast.

    Armorgard 541 provides a convenient work life. Armorgard 541 was designed from conception to be the ideal foam coating. The product is colored for an easy visual check of thickness.

    Armorgard 541 can be easily applied with a roller or brush. Normal application thickness is 15-30 mil (0.38-0.76 mm). Application varies depending on the porosity and roughness of the surface. A single build may be applied to horizontal surfaces up to 1/8" thick (125 mil or 0.3 cm). Armorgard 541 is conveniently packaged in 4 gallon, pre-measured kits, or bulk 5 gallon, 55 gallon and 275 gallon totes.

    COMPONENTS Resin, Hardener  
    DENSITY (MIXED) kg/l 0.99  
    MIX RATIO, pbv 5/1  
    COLOR Lt. Blue  
    MIXED VISCOSITY, cP or mPa.s 4,500 ASTM D 2196
    WORKING TIME, min 60  
    GEL TIME, min 90  
    TACK-FREE TIME, h 19-20  
    INITIAL CURE, h 24-30  
    70-80 (21-27)
    55-90 (13-32)
    COVERAGE* @ 15 mil or 0.38 mm, ft2/gal (m2/l) 107 (2.6)  
    HARDNESS, Shore D 79 ASTM D 2240
    * Varies with porosity of surface    

    Surface Preparation
    To achieve excellent adhesion, the substrate should be free of all loose and foreign material and should be clean. If present, any oils, greases, or other contaminates must be removed prior to coating. Armorgard 541 will not bond to a contaminated surface.

    Ambient Conditions
    Relative humidity and dew point must be determined before application to avoid adhesion failures. The dew point is used to predict the substrate temperature at which air begins to condense, in the form of water, on the substrate. Never apply a coating unless the form surface temperature is 5 °F (2.5 °C) above the dew point. This temperature difference must be observed until the epoxy coating is cured to a tack-free state. A dew point calculation chart is available from a Copps Technical Representative.

    Armorgard 541 will soften when exposed to extreme precast temperatures. A service temperature of no greater than 110 °F (43 °C) is recommended when removing forms coated with Armorgard 541.

    Mix 5 parts A (resin) to 1 part
    B (hardener) for 3 minutes using a Jiffy Mixer and a slow speed drill. Mix at slow speed (less than 850 rpm) to avoid air entrainment. DO NOT mix more material than can be used within the stated working time. REMEMBER - you will have less working time at higher temperatures.

    Armorgard 541 can be applied with a squeegee, brush, non-shedding roller or a grooved fiberglass roller. Re-coating a used foam piece may require a light sanding to remove any residue from previous casts.

    Armorgard 541, before it is fully cured (hard), may be removed from tools with Copps Enviro Kleen solvent or warm soapy water.

    Safety Precautions
    Avoid breathing of vapors. Forced local exhaust is recommended to effectively minimize exposure. NIOSH approved, organic vapor respirators and forced exhaust are recommended in confined areas, or when conditions (such as heated polymer, sanding) may cause high vapor concentrations. Do not weld on, burn or torch Armorgard 541 or any epoxy material. Hazardous vapor is released when an epoxy is burned.

    Avoid skin or eye contact. Wash skin with soap and water if contact occurs. If eye contact occurs flush with water for 15 minutes and obtain medical attention.
    Read and understand all cautions on can labels and material safety data sheets before using this material.

    Warranty and Disclaimer
    Copps Industries, Inc. gives no warranty, express or implied, and all products are sold upon condition that purchasers will make their own tests to determine the quality and suitability of the product. Copps Industries, Inc. shall be in no way responsible for the proper use and service of the product. The information given in this publication is considered to be accurate and reliable and is provided as a service only. Physical properties shown are typical. Actual properties are dependent on curing conditions and degree of cure. Any information or suggestions given are without warranty of any kind and purchasers are solely responsible for any loss arising from the use of such information or suggestions. No information or suggestions given by us shall be deemed to be a recommendation to use any product in conflict with any existing patent rights.
    TB#4541 (7/24/08)