Installation Floor Coating Procedures
|#890 Patching Epoxy (3 gal)|
|#1200 Epoxy Primer (27 gal)|
|#Vl-104 Epoxy base coat (24)|
|#CRU Urethane top coat (24)|
|#RT 130 thinner/reducer (10)|
Supplies May be Purchased through Image 2000
|18 Roller Skins (9)|
|18 Roller Cages (3)|
|#54 Aluminum Oxide (non-slip) (2 gal)|
|18 Roller Trays (2)|
|Plastic Ketchup Bottles (10)|
Supplies Purchased Locally
|Simple Green Detergent 8 gal|
|Muratic Acid 40 gal|
|3 - 4 Drill Blade Mixer 1|
|2 Drill Blade Mixer 1|
|Two gallon size Garden Sprinkler Pail 2|
|3 by 50 plastic 4mil roll 1|
|Bundle of Terry Cloth Towels 1|
|Vinyl Disposable Gloves 1 box|
|Three inch China Bristle Brushes 6|
|Five gallon size plastic pails 11|
|Motor Clay in Bag 1|
|Push Broom 30 2|
|Broom Handles 6 4|
Equipment Rentals Local
|Pressure Washer 3000 P.S.I. (1)|
|Floor Scrubber 17 with Nylo-grit type brushes (2)|
|Vacuum wet/dry (1)|
|Hand Drill 1/2 inch variable speed (1)|
|Moving Dolly small (1)|
|Trowel Edging 4 inch (2)|
|Turbo Washer (1)|
Installing an Image 2000 floor coating is a necessary sequence of steps as outlined below. Follow the outline, taking no short cuts, and your result will be a beautiful, safe, durable floor coating.
Sweep floor free of debris, dust and dirt.
Scrape and remove foreign materials: gum, plaster, paint over-spray, etc
Pressure wash floor to clean corners, cracks, & seams, etc. of dirt and debris.
Using 17 floor scrubbers with nylo-grit abrasive brushes scrub the floor with Simple Green to remove surface contaminants and excess curing agent.
To scrub floor with detergent proceed as follows: Using the two gallon sprinkler pails add two cups of Simple Green to two gallons of water and sprinkle on floor to wet floor completely. Scrub well with floor machine and immediately rinse with water from hose or pressure washer. Do not let soap dry before rinsing.
B. PREP AND ACID ETCHING
Acid etching is a critical procedural task, if instructions
are not followed it may negatively
affect the bonding of the coating.
When acid is applied to concrete which is alkaline, the reaction is very aggressive as the acid literally dissolves the concrete. This process creates a salt like substance waste product which looks like white dust and is formed by the acid and the calcium in the cement. This residue must be removed from the surface while the surface is still wet. If, after applying the acid to the surface, any portion should be allowed to dry, these salts will settle into the concrete pores and inhibit the bonding of the floor coating. Once these salts dry in the pores, they are almost impossible to remove.
A. Fill 2 gallon sprinkler pails 1/2 full of water then add acid to fill the pail @ acid water mix is 1:1 Note: Never pour water into acid always pour acid into water. NOTE: Wear protective gloves and boots and eye protective glasses as goggles. Muratic acid can give a sever burn to skin or eyes. If contact with occurs flush with water for 15 minutes.
B. Start with a small area of the floor 10 X 20 section to become familiar with the procedure. Do the floor in sections no larger than 800 square feet.
1. Using two gallon sprinklers pails, sprinkle acid on the floor to fully wet the floor, but not so much as to create puddles.
2. As one person is sprinkling acid have two people
With push brooms spread the solution so that acid is evenly distributed over the surface of the floor. Keep the acid/water mixture moving with the push broom for about 5 minutes. The acid reacts rapidly with the concrete and is being neutralized by the concrete. Because of this reaction process the broomers must spread the liquid immediately and continually upon contact with surface. After 5 minutes repeat the above process with one half as much acid solution being applied to the floor.
3. Immediately after the two 5 minute applications of the acid, remove the scale as follows: using method #1 preferred method Using a high pressure roto scale cleaner, clean the floor of the scale. You will usually be able to determine how slow to move the roto cleaner over the floor. If you are going too fast, you will see residue still on the floor. Usually a very slow walk is effective. After the floor has been roto cleaned, use the high pressure wand to remove scale from the edges and corners and rinse the floor thoroughly with pressure washer. Proceed to your next section and repeat the process.
After floor has been etched apply Simple Green detergent to entire floor and rinse of with pressure washer.
4. Method #2, Using a hose flush the acid application area with water and rinse off loose scale. Then apply Simple Green detergent to area and scrub thoroughly with the floor machine. While the scrubbers are moving have someone follow rinsing immediately behind the scrubbers. NO NOT ALLOW DETERGENT OR ACID RESIDUE TO DRY BEFORE IT IS RINSED OFF FLOOR.
Use the pressure washer to remove soap, and residue from corners and cracks.
5. Dry the floor with squeegees going over the surface. Vacuum the cracks, corners and holes. Allow the floor to air dry for 10 to 16 hours, or until it is visually dry. Tape a 4 foot by 4 foot piece of plastic over floor for one hour before coating, if dampness appears under plastic, floor is still too wet to coat.
Cracks, chips, and seams can be filled and patched with #890 epoxy as follows:
1. Using a soft bristle broom and #30 graded sand, back fill seams and cracks. Using the broom push the sand over the crack or seam and then broom out excess so that the crack or seam is filled to within 3/8 of the floor surface.
2. Product mixing #890 is a two component 100% solids epoxy. Once Part A and Part B are mixed you have 15 to 20 minute pot life, then mixture becomes too hot to use.
Mix small amount to start to determine how fast you are using it.
Mix product as follows:
Use a separate container as a mix pail.
1. Stir part A
2. Stir part B
3. Measure out (by volume) one part B and two parts A. Put these into the mix pail and mix with drill and mix blade for three minutes at slow speed.
NOTE: For filling cracks add two cups of mortar clay to I/2 gallon of mixed A & B and mix with drill mixer until mortar clay is evenly mixed.
For filling chips and sprawls product can be used as is.
4. Immediately pour the mixed product into the plastic application bottles (ketchup bottles) and apply the product.
For chips and sprawls squirt product into divot until full, then using a trowel, smooth the edges.
For cracks, apply a bead of 890 into and over filling the crack so an excess sits on the surface. Wait one half hour and scrape excess from the crack with a steel trowel.
Note: It takes about 8 hours at 70 degrees F. for the patches to cure enough to prime over the top. The patches may still be slightly soft when you prime but should be tack free.
For clarity of the writing, the procedures for mixing and
application of the coatings have
many common elements which are listed below.
All three products (the #1200 primer, the #UL104 base coat
and the CRU
aeroplate urethane) are two-component products requiring mixing of an A
component and a B component to make the final product.
Mixing procedures are as follows.
A. Use a separate pail as your mix pail @ 5 gallon plastic pail.
B. Prior to combining the A and the B stir well or mix with drill blade mixer the A and the B, as solids in each component settle to the bottom.
C. Once the A and the B have been premixed, pour the correct mix rate of A and B into the mix pail and mix for 5 minutes at a medium speed with the drill blade mixer. Do not whip the product or mix too fast as to draw air bubbles into the product.
D. Once the A and the B are mixed together the product has a pot life @ use time before it goes hot and cannot be used. Also, brushes and roller skins cannot be reused.
Once the A and the B are mixed, you have the following time @ pot life to apply the product so only mix what you can use immediately.
|Pot Life #1200 Primer 2 hours|
|Pot Life #UL104 Base Coat 2 hours|
|Pot Life CRU Urethane 1-1/2 hours|
All three products are applied by rolling using the 18 rollers and the 18 dip trays.
Note: Placing the dip tray on a small handtruck makes it easy to move the tray as you proceed.
Edges of the walls are painted (cut-in) with paint brushes.
Note: 3 natural bristle china chip brushes work the best to roller apply the product the procedure is as follows.
To roller apply the product, the procedure is as follows:
1. Dip roller into product in the tray and completely saturate the roller
Do not remove paint from roller. Just put it in the product and then bring it out on the floor.
2. Spread the product by rolling back and forth using a W pattern until product is evenly distributed. Then back roll the section.
Note: Try to keep in mind that you are not painting the product onto the floor, but rather you are spreading it. You want to evenly apply it with no puddles, but you want a good thick coverage.
1. #1200 Primer
A. Mixing The #1200 mix ratio is two-parts A to one part B all after mixing A and B together let product sit, @ dwell time, for 10 minutes before using.
Note: The #1200 primer is a thin product designed for absorption into the concrete. It can be rolled so as to cover the surface, but it is not recommended that it be rolled too thick.
Dry Time: At 70 degrees F. the primer should be tack-free and ready for the next coat in 8 hours.
Note: Some floors outgas creating air bubbles in the primer. If this occurs, scape the bubbles off using a 8-10 steel scraper prior to doing the next coat.
2. UL104 Base Coat
A. Mixing The UL104 mix ratio is one part A to one part B.
A.1 After mixing A and B together for 5 minutes add 1/3 gallon of RT130 thinner per 4 gallons of A+B mixture and mix for one minute.
Dry time: at 70 degrees the VL104 should be tack free and ready for the top coat in 10 hours.
NOTE: For best results scrape the VL104 coat using an 8 to 10 steel blade scraper to remove any bugs etc. that have gotten into the coat. Even though coat may look perfect small foreign material will be removed when you scrape.
#3 CRU Top Coat Aeroplate urethane
A. Mixing NOTE: To obtain the color you ordered, it is necessary to mix white, part A and gray part A. To insure a uniform color throughout the floor batch your gray and white part As as follows:
using (6) clean 5 gallon plastic pails put two gallons of white part A and one gallon of gray part B into each pail. Then batch the six pails by pouring from one pail to another until all 6 pails have been thoroughly cross mixed.
A-1 Measure out three gallons of the batched light gray part A and one gallon of part B and mix them in a clean 5 gallon pail.
A-2 After mixing A & B for 5 minutes add 1/4 gallon of RT130 thinner per 4 gallons of A plus B mixture and mix for 1 minute. Let product sit for 10 minutes of dwell time before using.
NOTE: The top coat is your appearance coat. Carefully back roll this coat to prevent roller marks.
INSTALLING THE NON-SLIP Aluminum Oxide
Installing the non-slip granules looks somewhat like feeding chickens.
Using one of the 12 oz ketchup bottles, cut the spout down so the spout opening is about 1/8 inch in diameter.
Fill the bottle with the granules. Pour about 1/2 teaspoon into palm of your hand. Throw the granules very high into air so they spread out and shower evenly down over an area about 4 foot by 4 foot.
Practice throwing on asphalt and watch the pattern that results.
The non-slip is applied during the rolling of the top urethane coat. After you roll a section throw the grit onto the wet coating , about two feet from the tack line so that the roller never touches the granules.