Transcript FlorLine Group

Polymer Floor & Wall Coatings:
Selection, Preparation, Installation
and Troubleshooting
System Selection Criteria
When designing a floor and/or wall system, selection of products
will depend upon working environment and severity of use.
• Physical:
Light foot traffic or heavy mechanized traffic?
Industrial process or laboratory/clean room?
• Chemical:
Cleaning agents, process chemicals, combinations.
• Temperature: Freezers, steam washdown, extreme ambient temps.
• Electro-static: High-voltage equipment, static-generating machinery
• Value Engineering: Floor design for the immediate environment
Multiple issues occurring over one area
Systems
When designing a floor and/or wall system, selection of products
will depend upon working environment and severity of use.
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Coatings
Slurries
Mortars
Urethane Cement
Wall systems
Coatings
Advantages:
Disadvantages:
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• Resistance to physical abuse
• Repair of poor substrate
conditions
• Less product for the same
amount of surface preparation
• Life-cycle costing
Inexpensive
Aesthetics
Cleanability
Concrete protection
Chemical resistance*
Coating Application
What is a Slurry?
Resinous coatings filled with aggregate (approximately 2
parts aggregate to 1 part resin) which is applied at 1/16”
to 3/8” in thickness.
Advantages:
Disadvantages:
• Great value/installed cost
• Significant improvement to
abuse compared to coatings
• Non-skid applications
• Resin-rich systems
• Moderate to good resistance to
physical abuse
• Will not resurface poor
concrete
• Thermal shock resistance
• Downtime
Slurry Application
What is a Mortar?
Resinous coatings filled with aggregate (approximately 4 or 5
parts aggregate to 1 part resin), which is applied by trowel and
finished. The systems range in thickness from 3/16” to 3/8”.
Advantages:
Disadvantages:
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• Cost
• Skill level required for
installation
• Resin-aggregate ratios
• Downtime
Resistance to physical abuse
Resurface poor concrete
Thermal shock resistance
Life-cycle costing
Mortar Application
What is a Urethane Cement?
Urethane emulsion combined with cement and silica sand
(approximately 3 parts aggregate to 1 part resin), which is
raked and finished at ¼” to 3/8” thickness.
Advantages:
Disadvantages:
• Great resistance to physical
abuse
• Bond in wet environments
• Thermal shock resistance
• Fast installations
• Chemical resistance
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Aesthetics
Cost
Limited colors
Skill level required for
installation
Urethane Cement Application
Wall Systems
High-build coating systems
Fiberglass reinforced epoxy systems
Flexible epoxy wall systems
Advantages:
Disadvantages:
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• Cost
• Substrate imperfections
• Downtime
Chemical resistance
Wash-down resistance
Impact resistance
Gloss retention
Cleanability
Aesthetics
Wall System Application
Concrete Requirements: Mix Design
Proper concrete mix design can produce a slab that is ideally
suited for bonding to a polymer topping.
• Standard mix design:
• Topical treatment: Seamless, film-building sealers, form release
• Fiber reinforcement: Coatings, self leveling floors 3/16”
• High early mix design:
• Concrete additives: Plasticizers, Gill 33
Successful Concrete
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Sub grade
Vapor barrier
Water to cement ratio
Aggregate selection and
gradation
• Finishing
• Curing
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“At-use” environment
Surface preparation
Moisture testing
Control conditions of
installation
• Dew point vs. surface
temperature during
installation
Concrete Concerns
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Moisture vapor transmission
Levelness of installation
Drain height
Lightweight concrete
Fly ash pozzolans
Moisture-related issues
Improper treatment of moisture-related issues can result in blisters,
delamination and potentially a complete floor system failure.
Moisture Measurement: A simple calcium chloride test will determine
the presence and force of any moisture migrating through the slab.
Acceptable levels vary with each system and manufacturer.
Causes:
Fast-track construction schedules
Mix design (wet pour)
Topical treatments (slow hydration)
Pouring slab in a pan
Ground or soil conditions
Humidity inside vs. outside
Chemistry changes in flooring products
Treatments for Moisture Problems
There are several techniques/products available for the
prevention and remediation of moisture-related problems.
• Slab design: vapor barrier, mix design
• Time: may not be on your side
• Temperature and humidity control
• Topical vapor barriers (Aqua Armor, Koester, FloorSeal)
• Product or System: water-based products, thin “breathable” coatings
and urethane cements
Scheduling & Planning for Work
A timely and efficient mobilization requires room preparation
and proper communication between Project Management,
Flooring Contractor, and all other trades.
Heat: Temperature must be at least 55*F for coatings and toppings.
65*F to 75*F is ideal for most systems. Room/slab temperature directly
affects coverage rates of product.
Light: The presence of finished lighting impacts application schedules,
cure time and aesthetics of finished floor.
Power supply: 220v 3-phase, 60 Amp. or 480v 3-phase, 30 Amp.
Installation equipment pulls total of amperage when starting up, and will
blow breakers.
Scheduling & Planning for Work
Effect on facility operations and return to service.
Other Trades: Damage to floors, walk off job site, power, lighting
Effect on existing operations: Product odor, contamination of
inventory, work areas adjacent to application, fire, safety
Slab Preparation
Chemical process: Effective in the removal of adhesives, oils, animal
fats. Acid etching, stripping, detergents.
Mechanical process: Shot blasting, grinding, scarifying, scabbling.
Water process: Water jet blasting is entirely dust free. Consider its effect
on product selection and time of application.
Dust Control: All slab prep machinery is connected to vacuum with HEPA
filtration.
Wrap-up
Return to service: Maximum allowable shut-down time can dictate the
type of system and product selected. Quick-cure polymers, such as MMA
and urethane concrete systems can greatly reduce application time and
return facilities to service in a matter of hours.
Application rates: Installation rates will vary with required prep work,
system selected, product manufacturer and schedule. Per-foot rates can
range from $2.00/ft. up to $12.00/ft. or more.