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duoMatrix-G is a
new polymer additive system for alpha gypsums that greatly
enhances physical and performance properties.
Be More Productive
- Matrix-G
castings can be demolded at a rate 4X faster.
Stronger
- Matrix-G greatly improves
the physical strength of castings. Matrix-G can be cast solid or
mixed with chopped fiberglass. This means far less breakage vs.
gypsum.
Lighter
- Matrix-G and fiberglass
matting or chopped strand will yield elements that are ultra-light
and ultra-strong. Matrix-G can be laid up by hand or machine
sprayed.
 Weather Resistance
- elements are
highly resistant to water, freeze/thaw and UV light.
Versatility
- Matrix-G is ideal for
adding metal powders to duplicate the look of real metal (i.e.,
bonded bronze), or other fillers such as calcium carbonate to
duplicate the look of real marble. Matrix-G can also be pigmented
or painted to achieve vibrant color effects.
Technical
Overview
duoMatrix–G™ is a three component system additive for alpha
gypsums: C-1 Latex, C-2 Resin and C-3 Hardener. When added in the
proper proportions, Matrix-G™ enhances the physical and
performance properties of alpha gypsums.
Mix Ratio for
bright white color
| Gypsum + |
C1 Latex + |
C2 Resin + |
C3
Hardener |
Pot Life |
Demold |
| 100 |
50 |
10 |
.05 |
45-60 minutes |
90-120 minutes |
| Example: |
| 10 lbs. |
5 lbs. |
1 lbs. |
.78 oz. |
45-60 minutes |
90-120 minutes |
| 4.5 kgs. |
2.27 kgs. |
.45 kgs. |
22 grams |
45-60 minutes |
90-120 minutes |
Pot Life and Demold times
can be reduced or extended with addition of an accelerator or
retarder. See "Accelerating and Extending" portions of
technical bulletin.
Density: 99 lbs./ft.3 (1.584 gms./cc)
Compressive Strength: 6,500 – 9,500 psi (457 - 668 kgs./cm3)
Tensile Strength: 3,300 – 5,500 psi (232 – 387 kgs./cm3)
Flexural Strength: 7,500 – 9,800 psi (527 - 689 kgs./cm3)
Impact Resistance: (175 in.lb./in2 (12.3 cm.kg/cm2)
Water Absorption: 0.25% weight after 24 hour water soak.
Freeze/Thaw Resistance: 300 cycles
Values were obtained using United States Gypsum FGR 95 Alpha
Gypsum. Maximum values were obtained using up to 14% glass fibers.
Values were obtained after 14 day air cure.
Preparation
Environment - Mixing of components
should be done at room temperature (70°F/22°C). Colder
temperatures will slow the working/cure time, while warmer
temperatures will reduce working times. Individual components
should be stored in a dry environment at room temperature. Humid
conditions will cause plaster and resin to lose effectiveness.
Freezing of latex will render it useless.
Mold Preparation - When solid casting
Matrix-G™ into a rubber mold, rinse the mold with a soap and
water solution (dishwashing soap diluted 1 part soap to 10 parts
water) prior to each casting. This will help minimize air bubbles,
facilitate demold, reduce build-up during production and give
longer mold life.
Preparation – Required Materials
Assemble all components and accessories before you begin. You will
need:
- Alpha Gypsum
- C-1 Latex
- C-2 Resin
- C-3 Hardener
- NIOSH Approved Dust Mask
- Window Screen Or Similar
For Filtering Mixture
- Measuring Containers
- Mixing Containers
- Weighing Scale (Digital
Gram or Triple Beam Balance)
- Mechanical / Power Mixer
(Jiffy or Squirrel Mixer)
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Matrix
Components: C1 + C2 + C3 + Alpha Gypsum
The Matrix-G™ base system consists of 3 components (C1 + C2 + C3)
that are blended with a hard gypsum.
Component 1 (C-1) Latex: A
white liquid that acts as a binder and gives dMG water resistant
properties.
Component 2 (C-2) Resin: Fine
white powder that reacts with component 2 and the Gypsum. Enhances
physical properties of overall mix.
Component 3 (C-3) Hardener:
Crystalline powder - looks like sugar. Different levels will
affect working / demold time.
Alpha Gypsum – You can not use just any
gypsum/plaster product. You must use an Alpha Gypsum such as FGR
95 from USG Corp., Densite HL from Georgia Pacific, Crystacal R
from British Gypsum or equivalent.
Important: Use only fresh materials . . . old materials (plaster,
latex) will give inconsistent results.
 Measuring Proportions
To minimize dust inhalation, we recommend
that you wear a NIOSH approved dust mask while weighing and mixing
components. An accurate scale (gram scale or triple beam balance)
is required to be successful with this product. Do not use a
postal, dietary or bathroom scale to weigh components.
Component amounts will vary depending on the size of the batch you
are making. Standard mixing proportions:
Parts By Weight
| Gypsum + |
C1 Latex + |
C2 Resin + |
C3
Hardener |
Pot Life |
Demold |
| 100 |
50 |
10 |
.48 |
30-35 minutes |
60-90 minutes |
| Example: |
| 10 lbs. |
5 lbs. |
1 lbs. |
.78 oz. |
30-35 minutes |
60-90 minutes |
| 4.5 kgs. |
2.27 kgs. |
.45 kgs. |
22 grams |
30-35 minutes |
60-90 minutes |
*Working times and demold times
will vary depending on mass and environmental temperatures.
Mixing Components In Sequence
Important: Components must be mixed in
proper sequence. A power mixer should be used to mix all
components.
Step 1 – Combine All Dry Ingredients Before Adding Liquid
Latex
Combine gypsum + C-2 Resin + C-3 Hardener by weight into a
suitable size mixing container. (If adding fillers such as chopped
glass, bronze powder, dry pigment, etc., blend with dry components
before adding C-1 Latex). Mix dry components thoroughly with
mixing paddle, power mixer, etc. until well blended.
Step 2 – Shake or Stir C-1 Latex Well, And Add Required
Amount
Pre-mix C-1 Latex with power mixer. Sift powder contents into
required amount of C-1 Latex by weight and mix all components with
a power mixer until all dry powder components are thoroughly
dispersed (minimum 90 seconds). Be
Sure To Shake or Stir C-1 Latex!!
Pouring Into A Mold . . . Applying A Face
Coat . . . "Screen Pouring"
After thoroughly mixing components, the mixture is ready to be
poured into a mold. For best results:
1. Brush a face coat of Matrix onto the surface of the mold. This
helps to break surface tension and ultimately reduce air bubbles.
2. After a face coat is applied, the remaining mixture is slowly
poured through a window screen, kitchen colander or equivalent
into the mold. This will help eliminate any unmixed product and
help to further reduce entrapped air.
Further Reducing Entrapped Air . . .
Air bubbles are sometimes a concern with polymer modified gypsums
and will vary depending on conditions. There are additional steps
you can take to help reduce entrapped air:
1. Vibrating – concrete casters often vibrate their concrete
mixtures on a vibration table to reduce entrapped air. By
vibrating the mold, air will rise and dissipate on the surface.
2. Pressure – Required: Pressure Vessel and Compressor. After
mixture is poured into mold, place mold in a pressure vessel and
subject mixture to 60 PSI (4.2 kg/cm2) air pressure for one hour.
Pressure Casting is the only way to completely eliminate bubbles
from your mix. Vacuuming material does not work.
Accelerating duoMatrix™
Matrix-G™ Accelerator (powder) will reduce the demold time of
Matrix-G and should be pre-mixed with dry components before adding
latex. Note: The shorter the desired demold time, the shorter the
working time.
Parts By Weight for Accelerating
| Gypsum + |
C1 Latex + |
C2 Resin + |
C3
Hardener |
Accelerator |
Working
Time |
Demold |
| 100 |
50 |
10 |
.48 |
.96 |
4 minutes |
10-15 minutes |
| 100 |
50 |
10 |
.48 |
.32 |
7 minutes |
20-25 minutes |
| 100 |
50 |
10 |
.48 |
.12 |
15 minutes |
50-55 minutes |
Slowing Matrix-G™
Some applications may call for a large
quantity to be mixed and poured in a single mold (mass casting) or
for "master batching" (a large amount is mixed and
poured into many different molds for production casting). Reducing
Matrix-G™ Hardener (C-3) will give a longer working time and
demold time.
Parts By Weight for Slowing
| Gypsum + |
C1 Latex + |
C2 Resin + |
C3
Hardener |
Working
Time |
Demold |
| 100 |
50 |
10 |
.12 |
55 minutes |
80-90 minutes |
| 100 |
50 |
10 |
0 |
60 minutes |
120-150 minutes |
Making Architectural Elements – Hand
Lay-Up Technique
Matrix-G™ can be used to make architectural elements - both
interior and exterior. With the addition of glass fibers in the
form of fiberglass matting or chopped fibers, Matrix-G™ can be
"layed up" to make elements that are thin, lightweight
and exceptionally strong. For exterior use, applying a sealer or
painting the element is recommended.
Fiberglass Surface Matting (i.e. SURMAT from Nico Fibers, Inc.) is
most commonly used for making large architectural panels. Chopped
fiberglass (i.e. 1/2" strand from Nippon Electric or Cem-fil)
is used for making smaller elements.
Hand Lay Up Using Fiberglass Matting . . .
Mix Matrix-G™ at the "standard" mix ratio and brush a
surface or "gel" coat into a mold. Let cure one hour or
until Matrix-G™ gels. Mix another batch and brush a layer over
initial gel coat. Lay matting over fresh material and let material
penetrate matting – brush with clean paint brush and apply light
pressure over surface to minimize entrapped air. After a uniform
coating is attained, apply another layer of matting and brush
again. Apply a minimal amount of Matrix-G™ – just enough to wet
out the surface. Repeat as necessary until 3/8" (1 cm.)
thickness is attained.
The number of matting layers will vary according to matting
thickness. For example, if using 10 mil. matting, 15 layers are
necessary to build a suitable thickness (3/8" – 1 cm).
The composite mixture over the face mix should have a minimum
thickness of 3/8" (1 cm) and contain 5% - 10% glass fiber
reinforcement.
Hand Lay Up Technique Using Chopped Glass
Another technique for making strong, lightweight elements is to
mix chopped fiber directly into the Matrix-G™ standard mix.
Generally, ¾" "AR" grade chopped fiber works best.
"E" grade can also be used. Adding chopped fiber takes
much less time than layering chopped matte.
How To Proceed . . . The chopped fiber is added as a percentage of
the total weight. Fiber can be added in concentrations of 3% to
12%. For best results, 6% chopped fiber should be added.
Mix Matrix-G™ at the "standard" mix ratio and brush a
surface or "gel" coat into mold. Let cure one hour or
until material gels. Next, calculate required total weight of
Matrix-G™ (C-1 + C-2 + C-3 + Gypsum). Required amount of chopped
fiber will be 6% of this amount. Add chopped fiber to dry
components (C-2 + C-3 + Gypsum) and mix thoroughly. Add C-1 Latex
and mix thoroughly again with power mixer.
Apply mixture with gloved hand or spatula over gel coat. Another
application may be required to attain 3/8" (1 cm) thickness.
Spraying duoMatrix-G™
For making large architectural panels or for covering large areas,
Matrix-G™ can be sprayed using standard spray equipment (normally
used to spray cementitious materials). Matrix-G™ is mixed at its
standard mix ratio with chopped glass and is then poured into the
spray gun "hopper" where it is then forced through the
spray equipment and out the spray nozzle. For information about
spray equipment, contact duoMatrix, Inc.
Post Finishing
After elements have fully cured, they can be sanded or sand
blasted to achieve the desired surface texture.
"Wet Sanding" is advisable to minimize dust particles
and build up on sand paper.
For Exterior Use, Apply A Sealer . . .
Because Matrix-G™ system substantially reduces the water
absorption rate (0.25%) of alpha gypsums, elements made with
Matrix-G™ are suitable for exterior use. Elements must, however,
be sealed with a suitable sealer such as "Thorough Seal"
brand sealer or Sherwin Williams "Terrazo Sealer".
Elements can also be painted with an outdoor acrylic paint.
Making "Cold Cast Bronze" Elements
Reproducing the look of bronze is a common application for
Matrix-G™ because you can achieve the look of real bronze at a
fraction of the cost. Three different techniques can be used, and
are described in full detail in a separate technical bulletin
available from duoMatrix, Inc. For making solid castings, the
following proportions will work well. –325 mesh bronze powder is
recommended and should be pre-mixed with dry Matrix-G™
components prior to adding C-1 Latex.
Parts By Weight for "Cold Cast Bronze"
| Gypsum + |
C1 Latex + |
C2 Resin + |
C3
Hardener |
Bronze
Powder |
| 100 |
70 |
10 |
.48 |
150 |
Metal powders (bronze, copper and
brass) are available from duoMatrix, Inc. or your duoMatrix
distributor.
Post Finishing Cold Cast Bronze Elements
To bring forth the metallic finish, buff with steel wool or sand
paper (400 grit). Patina coloring can then be done using cupric
nitrate (green) or ferric nitrate (yellow). Casting should then be
sealed with wax or clear acrylic spray to prevent oxidation.
Adding Pigments And Fillers . . . Use Your
Imagination
Because Matrix-G™ blends easily with different materials,
realistic effects can be achieved with the addition of various
pigments and/or fillers. Liquid or dry pigments can be added
during mixing. Other metal powders can be added to attain specific
metal finishes (copper, pewter, silver).
A marble finish can be attained by adding marble dust (calcium
carbonate). Granite crystals will give a granite look. Adding
malachite will give a realistic porcelain finish. Wood grain
finishes can be attained by adding powdered pecan shells or
similar fillers.
Metal powders and fillers are pre-mixed with dry components by
weight. Amount of filler to be added depends on desired effect.
Some experimentation may be necessary.
duoMatrix™ unit packaging is as follows:
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Size |
C-1 Latex |
C-2 Resin |
C-3 Hardener |
Gypsum Needed |
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Gallon Unit* |
8 lbs. (3.63 kg) 1.6 |
lbs. (0.726 kg.) |
1.25 oz. (35 gms) |
16 lbs. (7.25 kg.) |
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5 Gallon Unit |
40 lbs. (18.15 kg.) |
8 lbs. (3.62 kg.) |
6.20 oz. (176 gms) |
80 lbs. (36.3 kg.) |
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55 Gallon Drum |
460 lbs. (254 kg.) |
100 lbs. (45.36 kg.) |
4.8 lbs. (2.19 kg.) |
920 lbs. (417.3 kg.) |
*Sold as units only. Individual
components not sold separately.
Accelerator—Will reduce demold time of
duoMatrix-G system. Available in three convenient sizes.
1.59 oz. (45 g.)
1 lb. (454 g.)
12 lbs. (5.4 kg.)
duoMatrix-G™ and duoMatrix-C™ as well
as accessories are available from distributors.
To locate your nearest distributor, contact duoMatrix at the
numbers listed below. duoMatrix, Inc. is a division of Smooth-On,
Inc. Technical help is available from technicians by phone, fax or
internet.
Call us anytime with questions send us feedback
on our products or Web site.
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