TotalBoat High Performance Epoxy System Troubleshooting Guide

• The epoxy did not cure
• The epoxy is still sticky after a long duration
• Isolated areas of uncured epoxy
• Striations in the cured epoxy

• Both components were not mixed together thoroughly
• Improper mix ratio of the resin and hardener
• A substance was mixed with the epoxy before the resin and hardener were thoroughly mixed together
• Need to wait longer for epoxy to cure
• Cooler conditions lead to longer than desired cure time
• Contamination
• An overabundance of any substance mixed in with the epoxy, which is not the resin or hardener component, that may have diluted the epoxy too much, or reacted with it chemically

• Allow the epoxy another 24 hours to cure. If it does not cure to the desired hardness/tack-free state, mechanically remove the uncured epoxy and start over, taking extra care to follow all surface preparation, mixing, and application procedures with better care.
• Take extra care to mix TotalBoat High Performance epoxy at the specified 2:1 mix ratio (by volume).
• Only apply TotalBoat High Performance epoxy when the environmental conditions are within the specified range to ensure a proper cure, within the desired timeframe.
• Only use approved fillers, thickeners, pigments, colorants, or other additives. Do not add solvents to thin the epoxy.
• Always mix the resin and hardener components prior to adding any fillers, thickeners, colorants, tints, or other substances.
• Do not subject the curing epoxy to high humidity, dew, rain, or water spray until it has become tack-free. For cosmetic applications, wait a minimum of 24 hours after it has become tack-free before subjecting the epoxy to high humidity, or any other contact with water.
• Only use the specified solvents when working with High Performance epoxy.

High Performance epoxy cured properly but did not adhere to the substrate

• Incompatible substrate
• Contamination
• Improper surface preparation

• Only apply TotalBoat High Performance epoxy to acceptable substrates. Substrates that are not listed as ‘acceptable’ may not allow for a sufficient bond.
• Mechanically remove High Performance epoxy from any areas that show poor adhesion or delamination.
• Start all surface preparation over from the beginning, taking extra care and attention to detail. Do not cut corners or make substitutions.

Epoxy cured white, or with white spots

• Moisture is the most common source of white spots that are present when epoxy finishes curing.

• Take extra care to prevent moisture or water from coming in contact with epoxy until it has finished curing
• When applying epoxy to wood or other potentially porous/damp substrates, verify that the moisture content is within the acceptable range.
• Sufficient moisture can lead to premature delamination. If delamination is a concern, mechanically remove the epoxy and start over, taking extra care to ensure that moisture is not a factor.

Bubbles in the cured epoxy

• High Performance epoxy was applied to a porous substrate
• Bubbles were whipped into the epoxy while mixing
• Contaminant/substance that reacted with the epoxy/is not compatible

• Always mix epoxy products very thoroughly, ensuring that there are no resin- or hardener-rich areas, however whipping the epoxy excessively can induce air bubbles that have to try and float to the surface. For cosmetic or thicker applications, take extra care not to whip air bubbles into the epoxy while mixing

Epoxy turned yellow, and/or has cracks that showed up during the cure process

• Excessive heat generated during the cure —this can also make the epoxy hard and brittle
• Direct exposure to high levels of UV radiation while curing
• The fast hardener may impart a slight yellow color —this is normal

• For any applications where maximum clarity is desired, the Slow and Medium hardeners are recommended
• Avoid dispensing and curing in extreme levels of UV exposure
• Dispense and cure smaller masses of epoxy to avoid creating an excessive exothermic reaction.
• Follow the maximum pour depths posted on the Application Chart on the Technical Data Sheet.
• Mechanically remove any undesirable looking yellowed epoxy, perform all surface preparation over, and reapply High Performance Epoxy, taking more care to avoid generating excessive heat, or exposing it to excessive UV exposure.

Epoxy turned yellow over time (not from the curing reaction)

• Excessive temperature
• Excessive exposure to moisture
• UV exposure

• Epoxy is inherently not UV stable. A UV stable coating should be applied to any High Performance epoxy applications that require UV stability to ensure maximum clarity retention.
• For cosmetic applications, avoid storing cured epoxy

One epoxy component or the other seems very thick, lumpy, or has small crystals

• Ambient temperature is below the recommended application temperature, increasing the viscosity of the liquid epoxy component
• Crystallization has occurred in the liquid epoxy component.

• Always store epoxy components as directed on the product, or on the Technical Data Sheet.
• Dispensing and applying High Performance Epoxy at lower temperatures than recommended may lead to the epoxy components having a higher viscosity than desired.
• Follow the crystallization remediation process outlined on the Technical Data Sheet if the viscosity and consistency does not resolve by bringing the liquid epoxy components back to the specified storage conditions.

Did not cure with a smooth, shiny surface

• Excessive exothermic reaction
• Higher moisture content was present during the cure
• An amine blush has formed on the surface
• Improper mix ratio, or poor mixing of the resin and hardener and components

• If the epoxy has not cured completely, wait another 24 hours. Mechanically remove any epoxy that is uncured at that point and start over.
• For all other scenarios: Wash the surface with warm water and a mild soap, then rinse thoroughly and dry the surface completely. Sand the surface until any undesirable epoxy has been removed. Remove all sanding residue and reapply High Performance epoxy as desired, taking extra care when mixing and applying, as well as following all specified environmental conditions to ensure the best results.

Paint, primer, or other form of topcoat did not adhere to High Performance epoxy

• Improper surface preparation
• Incompatible material being applied to High Performance Epoxy
• High Performance epoxy was not sufficiently cured
• Gelcoat should not be applied directly to High Performance epoxy without using one of the specified TotalBoat epoxy primer products first.

• Ensure product compatibility before applying any coatings or topcoats to High Performance epoxy.
• Ensure that High Performance epoxy has cured for a sufficient amount of time before beginning any surface preparation.
• Follow the surface preparation based upon the specific topcoat, as outlined in the Technical Data Sheet, and the product being applied.
• Do not cut any corners when performing the surface preparation.
• Remove any coatings that have not adhered properly, and start over taking extra care to the surface preparation and application instructions.

Colorants/dyes/tints did not achieve the desired finish, or settled

• Test sample was not performed to observe the final product.
• Tints, dyes, or pigments that do not go into solution with the liquid epoxy may float or sink depending on their density relative to that of the epoxy. High Performance epoxy has a low viscosity when mixed. The low viscosity allows any added materials that do not go into solution, that have a different density than the epoxy, to settle up or down at a faster rate than viscous epoxies.

• Always perform a test sample of High Performance epoxy with any tints or colorants prior to using them on the final project, to see if the desired results are achieved.
• Pigments and special effects that do not mix into the epoxy in a liquid form, such asmica powder pigments, may settle or float to the surface of the epoxy if they are added too soon. These types of pigments or additives can be added as soon as the epoxy begins to warm from the reaction, but is still a flowing liquid.
• Mechanically remove any epoxy that did not achieve the desired effect.

Cracks appeared in the area of a fiberglass, or other reinforcement fabric repair spot

• Excessive epoxy was applied, and insufficient reinforcement fabric was used
• Verify that the correct reinforcement fabric was used for the application

• Do not use ‘extra’ epoxy when performing repairs. Only use enough to sufficiently wet out the fabric. The fabric is the strength of any repair.
• Ensure that the proper laminate schedule was used for a repair. For serious or specific structural repairs, an engineer or specialist may need to be consulted.
• Use sufficient reinforcement fabric for a repair.
• Select the appropriate reinforcement fabric was chosen for a given application based upon their strength properties.

Delamination of a fiberglass, or other reinforcement fabric repair spot

• Poor surface preparation
• Repaired area was stressed prior to being sufficiently cured
• Incompatible substrate
• The laminate was ‘dry’, or had insufficient epoxy saturation

• Completely remove any partly delaminated repairs.
• Ensure that the substrate is a compatible material for TotalBoat High Performance epoxy.
• Perform all surface preparation over again ensuring that extra care is taken.
• Perform the repair laminate again, and sure sufficient epoxy saturation, and sufficient time for the repair to cure prior use or stressing the repair.