AWLFAIR EPOXY PUTTY BASE

What is Awlfair Epoxy Putty Base and why choose it?

Awlfair Epoxy Putty Base (Awlfair LW system, D8200 base with D7200 converter) is a premium trowelable epoxy fairing compound designed to level, fair and smooth surface imperfections such as gouges, pitting, dents and weld seams. It creates a level, even surface that reduces drag and improves the appearance of the hull. The system can be used both above and below the waterline and is suitable for professional fairing work where a super-smooth, easily sandable finish is required.

Formulated as a lightweight, high-build epoxy filler, it allows application in relatively thick layers, develops strong mechanical properties and can be machine or block sanded to very tight fairing tolerances on large yacht and boat hulls.

Main features

• Premium epoxy fairing compound: two-component system (white base D8200 + red converter D7200) for professional marine fairing.
• Super-smooth finish and easy sanding: specifically designed to give a smooth, fair surface that can be sanded with 36–80 grit paper once cured.
• Above and below waterline use: suitable for fairing both underwater hull (when correctly sealed) and topsides/superstructures.
• High build per coat: recommended dry film thickness of up to 6 mm per application (maximum 5–6 mm DFT per coat to minimise air entrapment).
• High solids, low shrinkage: volume solids approximately 96% with specific gravity around 0.91 for lightweight but robust fairing.
• Excellent mechanical strength: high compressive, tensile and flexural properties for durable fairing systems.
• Compatible with Awlgrip epoxy primers: designed to work over Awlgrip Hullgard Extra Epoxy Primer and High Build (GRP only), and to be sealed with Awlgrip epoxy primers before topcoating.
• Manual or automatic mixing: can be hand-mixed to a uniform pink colour or processed through approved automatic mixing machines.

Technical specifications

Product and packaging

• Product type: two-component trowelable epoxy fairing compound.
• Base component: Awlfair LW White Base D8200.
• Converter component: Awlfair LW Converter Red D7200.
• Available pack sizes (system): 1 US Quart, 1 US Gallon (US only), 2 US Gallon, 5 US Gallon, 60 L (EU only), 200 L (EU only).
• Typical uses: professional, industrial and consumer fairing of marine structures; two-component filler for interior and exterior use.

Physical data

• Volume solids: 96% (Awlfair LW system).
• Specific gravity: approx. 0.91 (mixed system).
• VOC content (mixed 1:1 by volume): approx. 42 g/L (0.35 lb/gal); 46 g/kg (0.05 lb/lb) – theoretical values.
• Flash point (base): approx. 149°C (closed cup, Pensky-Martens).
• Appearance (base): white paste/solid.

Theoretical coverage and film thickness

• Application tools: longboard battens, trowels, spatulas, putty knives.
• Recommended wet film thickness per coat: 6000 µm (approx. 6 mm / 240 mil).
• Recommended dry film thickness per coat: 6000 µm (approx. 6 mm / 240 mil).
• Maximum dry film thickness per coat: 10000 µm (approx. 10 mm / 400 mil), but a maximum of 5–6 mm per application is recommended to minimise air entrapment.
• Theoretical coverage at recommended DFT: approx. 0.17–0.63 m²/L (around 6.8–6.9 ft²/gal), depending on data set; actual coverage depends on equipment, technique, part size and conditions.

Mechanical properties (typical, hand-mixed product)

• Compressive strength: 66 MPa at -20°C; 60 MPa at 0°C; 47 MPa at 20°C.
• Compressive strain: 6% at -20°C; 6% at 0°C; 5% at 20°C.
• Tensile strength: 19 MPa at -20°C; 23 MPa at 0°C; 20 MPa at 20°C.
• Tensile strain: 0.5% at -20°C; 0.8% at 0°C and 20°C.
• Tensile modulus: 3541 MPa at -20°C; 3041 MPa at 0°C; 2527 MPa at 20°C.
• Flexural strength: 42 MPa at -20°C; 39 MPa at 0°C; 36 MPa at 20°C.
• Flexural strain: 1.6% at -20°C; 1.5% at 0°C; 1.6% at 20°C.
• Flexural modulus: 2874 MPa at -20°C; 2596 MPa at 0°C; 2272 MPa at 20°C.
• Thermal expansion coefficient: 8 × 10⁻⁵ /°C.

Mixing and application

• Mix ratio (base:converter): 1:1 by volume; 1.59:1 by weight (D8200:D7200).
• Thinning: do not add reducers, solvents or thinners of any kind.
• Mixing: blend components thoroughly to a uniform pink colour with no streaks, lumps or strings.
• Application temperature range: do not use below 13°C (55°F) or above 40°C (104°F).
• Application method: apply by trowel/spatula/batten to areas that can be worked within 15–20 minutes, starting with thin coats (up to 6 mm) in low areas and building out to high areas.

Drying and recoat times (typical)

• Touch dry: approx. 16 h at 15°C; 8 h at 25°C; 5 h at 35°C.
• Hard dry: approx. 48 h at 15°C; 24 h at 25°C; 16 h at 35°C.
• Sandable: approx. 48 h at 15°C; 17 h at 25°C; 6.5 h at 35°C.
• Hardness development (Shore D): around 60 ±10 after 48 h at 15°C; 24 h at 25°C; 16 h at 35°C.
• Pot life: approx. 2.5 h at 15°C; 1.5 h at 25°C; 45 min at 35°C (warmer temperatures reduce pot life).
• Overcoating window with approved high-build primers (e.g. Epoxy Surfacing Primer, High Build, Sprayable Fairing Compound, Ultra Build, Awlfair Surfacing Filler): minimum 42 h at 15°C, 17 h at 25°C, 6.5 h at 35°C; maximum – extended (no fixed maximum stated) provided surface is correctly sanded.

Applications and use cases

Typical substrates and systems

• Substrate primers: apply only over properly applied and prepared Awlgrip primers such as Hullgard Extra Epoxy Primer and High Build (GRP only).
• Direct over Hullgard Extra: Awlfair LW may be applied directly to Hullgard Extra without sanding.
• Over High Build: High Build must be sanded before applying Awlfair LW.
• Below waterline: Awlfair LW must be sealed with Hullgard Epoxy Primer (D6070/D3707) or another suitable epoxy primer when used below the waterline.
• Above waterline: should be sealed with an Awlgrip Epoxy Primer such as High Build or Ultra Build to maximise gloss and colour holdout of Awlgrip topcoats. Awlgrip Surfacing Filler may be applied over Awlfair LW to fill pinholes and sanding marks before priming.

Marine fairing scenarios

• Hull fairing (underwater and topsides): smoothing irregularities, weld seams, dents and pitting on steel, aluminium or GRP hulls that have been correctly primed.
• Superstructure and deck structures: cosmetic fairing to achieve a high-quality finish before high build primers and topcoats.
• Refit and repair: rebuilding damaged or corroded areas to restore original lines, followed by sanding with longboards or machines to achieve project-specified fairing standards.
• Large-area levelling: multi-coat applications on extensive surfaces; several passes may be needed to build up to the final profile, always respecting the 5–6 mm maximum per application.

FAQ – Awlfair Epoxy Putty Base (Awlfair LW System)

1. Can Awlfair LW be used both above and below the waterline?

   Yes. Awlfair LW can be used above and below the waterline. When used below the waterline it must be sealed with a suitable epoxy primer such as Hullgard Epoxy Primer. Above the waterline it should be sealed with an Awlgrip epoxy primer such as High Build or Ultra Build.

2. What is the correct mixing ratio for the base and converter?

   The mix ratio is 1:1 by volume (Awlfair LW White Base D8200 : Awlfair LW Converter Red D7200), or 1.59:1 by weight. Mix thoroughly to a uniform pink colour with no streaks or lumps.

3. Can I thin Awlfair LW with solvent?

   No. Reducers, solvents or thinners of any kind must not be added. The product is designed to be used unthinned.

4. What is the maximum thickness I can apply in a single coat?

   The recommended maximum dry film thickness per application is 5–6 mm to minimise air entrapment. Although up to 10 mm DFT is listed as a theoretical maximum, thicker applications increase the risk of air pockets and system failure.

5. How long do I have to wait before sanding?

   Typical sanding times are about 48 hours at 15°C, 17 hours at 25°C and 6.5 hours at 35°C. Actual times will vary with temperature and film thickness; curing continues for several days even when the surface appears hard dry.

6. What grit paper should be used for sanding?

   Block or machine sand with 36–80 grit abrasive (typically P36–P80). Longboard or machine sanding is recommended for fairing large areas.

7. Which primers are compatible with Awlfair LW?

   Awlfair LW is designed to be applied over Awlgrip primers such as Hullgard Extra Epoxy Primer and High Build (GRP only). After fairing, it must be overcoated with an approved high-build epoxy primer such as High Build, Ultra Build, Epoxy Surfacing Primer, Sprayable Fairing Compound, Hullgard Epoxy or Awlfair Surfacing Filler (as per project specification).

8. What is the recommended application temperature range?

   Do not apply Awlfair LW at temperatures below 13°C (55°F) or above 40°C (104°F). Conditions outside this range can affect application properties and curing.

9. Can Awlfair LW be mixed using automatic equipment?

   Yes. It can be mixed with suitable automatic mixing machines. Automatic mixing generally increases product density and alters mechanical properties but can offer productivity and health and safety benefits. Follow equipment manufacturer and local Awlgrip technical guidance.

10. How can I reduce the risk of air pockets in the fairing compound?

    Apply in layers no thicker than 5–6 mm, work the material firmly with the trowel, remove and refill any visible voids and chamfer edges between passes. Avoid excessive use of battens, as they can create air pockets, and remove any remaining pockets so that they are less than 4 mm.

14. Transport information

The following transport data refer to Awlfair LW White Base as supplied and are based on the safety data sheet information.

• UN number: UN3077.
• Proper shipping name (ADR/RID, IMDG, IATA): ENVIRONMENTALLY HAZARDOUS SUBSTANCE, SOLID, N.O.S. (reaction product: bisphenol-A-(epichlorohydrin) epoxy resin; formaldehyde, oligomeric reaction products with 1-chloro-2,3-epoxypropane and phenol).
• Transport hazard class: Class 9 (miscellaneous dangerous substances and articles).
• Packing group: III.
• Marine pollutant: yes (IMDG – environmentally hazardous; contains epoxy resin and formaldehyde-epoxy oligomers).
• ADR/RID, IMDG, IATA special note: when transported in inner packagings of ≤5 L or ≤5 kg, and where packaging meets the general provisions of the applicable regulations, the product is not regulated as a dangerous good.
• Special precautions for user: within user’s premises, always transport in closed, upright and secure containers. Ensure personnel know procedures in case of accident or spillage.

8. Personal protective measures

The information below is taken from the Awlfair LW White Base safety data sheet and is intended for risk assessment and selection of individual protection during handling, mixing, application and sanding.

General hygiene

• Wash hands, forearms and face thoroughly after handling and before eating, drinking or smoking.
• Do not eat, drink or smoke in areas where the product is handled, stored or processed.
• Remove contaminated clothing and protective equipment before entering eating areas; wash contaminated clothing before reuse.
• Ensure eyewash stations and safety showers are available close to the work area.

Skin and hand protection

• Wear chemical-resistant, impervious gloves compliant with an approved standard.
• Recommended glove type: nitrile rubber, thickness ≥ 0.12 mm, protection class 2 or higher according to EN374 (breakthrough time > 30 minutes).
• Inspect gloves regularly and replace if damaged or degraded.
• Wear suitable protective clothing (e.g. coveralls, apron, boots) selected according to task-specific risks.

Eye and face protection

• Use safety eyewear conforming to relevant standards when there is a risk of splashes, mists or dust.
• Chemical splash goggles are recommended when mixing, applying or sanding the product.

Respiratory protection

• If ventilation is insufficient or dust/vapour levels exceed applicable limits, wear suitable respiratory protection.
• Recommended type: respirator conforming to EN140 with A/P2 filter or better.
• Ensure respirators are used within a formal respiratory protection programme, including fit testing and training.
• Dry sanding, flame cutting or welding of the dry film can generate hazardous dust and fumes; use wet sanding where possible and appropriate respiratory protection when exposure cannot be avoided.

Environmental and handling precautions

• Avoid release to the environment; the product is toxic to aquatic life with long lasting effects.
• Use local exhaust ventilation or other engineering controls if user operations generate dust, fumes, gas, vapour or mist.
• Keep containers tightly closed when not in use and store in a dry, cool, well-ventilated area away from incompatible materials.

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