Construction of industrial self-leveling epoxy flooring
RELATED MATERIALS
DUROFLOOR Two-component, self-leveling epoxy flooring
DUROFLOOR-PSF Two-component, solvent-free epoxy primer
DUROPRIMER Two-component epoxy primer
DUROFLOOR-R Two-component, brushable epoxy coating
DUROFLOOR 11 Two-component epoxy flooring
I. NATURE OF THE PROBLEM – REQUIREMENTS
Floors in factories, workshops, warehouses, garages, abattoirs, hospitals etc. are constantly exposed to heavy mechanical wear (e.g. friction, impact etc.) and chemical damage from thinned, inorganic and organic acids, alkalis, petroleum products, wastes, oils etc.
Therefore, the final surface on such floors needs to have considerable mechanical and chemical strength as well as being easy to clean.
Industrial floors made from concrete, even those made with surface hardener and mechanical grinding, but especially those from ordinary concrete or terrazzo, do not usually meet the above requirements (e.g. they do not resist chemical effects from acids, get dusty etc).
II. SOLUTION
The application of DUROFLOOR or DUROFLOOR 11, self-leveling epoxy floorings, on concrete floors, successfully meets requirements for high mechanical and chemical strength, and provides a good aesthetic finish.
DUROFLOOR and DUROFLOOR 11 are colored, self-leveling, 2-component solvent-free epoxy systems, which can be applied at a thickness of 2-3 mm. Once they have hardened, they form an easily cleaned final surface that displays great durability and strength against friction (abrasive resistance) as well as resistance to chemical effects, e.g. to diluted organic and inorganic acids, alkalis, petroleum products, wastes, water, sea water etc.
III. APPLICATION
Substrate preparation
The surface on which the epoxy coating is going to be applied, must be dry (<4% moisture) and stable, free of dust, loose particles, grease, etc. and protected from underneath moisture attack.
The substrate must be properly prepared, e.g. by grinding, sand blasting, pellet blasting, milling, etc., in order to open the pores to allow penetration of the primer and ensure better anchoring and bonding of the epoxy coating.
Subsequently, the surface should be carefully cleaned with a high suction vacuum cleaner.
The properly prepared surface (as described above) is then primed with DUROFLOOR-PSF or DUROPRIMER epoxy primer.
Consumption: 200-300 g/m².
On iron or steel surfaces, priming with EPOXYCOAT-AC, anticorrosive epoxy coating takes place in 2 layers. Second layer follows, after the first one is completely dry, but within 24 hours.
Consumption of EPOXYCOAT-AC: 200-300 g/m²/layer.Once the primer is dry, any imperfections in the surface (cracks, holes) should be filled and repaired with DUROFLOOR (A+B), mixed with grade 0-0.4 mm quartz sand (or Q35 sand), in the ratio of 1:2 to 1:3 by weight, or with DUROFLOOR 11 (A+B) mixed with quartz sand, with a particle size of 0.1-0.4 mm (or M32), in the ratio 1:1.5 up to 1:2 by weight, or using DUROFLOOR-PSF mixed with quartz sand, with a particle size of 0-0.4 mm (or Q35) in proportions of 1:2 up to 1:3 by weight.
Application of DUROFLOOR or DUROFLOOR 11 self-leveling epoxy floorings, should take place after priming, but within 24 hours.
Application of DUROFLOOR or DUROFLOOR 11
Application of DUROFLOOR
Mixing of DUROFLOOR components
Components A (resin) and B (hardener) are packaged in containers with predetermined mixing proportions. The whole quantity of component B should be added to component A and the mixture is stirred for approx. 5 minutes with a low-revolution (300 rpm) mixer. It is important that stirring reaches the wall and bottom of the container as well, in order to achieve uniform dispersion of the hardener. Subsequently, quartz sand with particle-size 0-0.4 mm (or Q35) is gradually added into the mixture under continuous stirring, in proportion 1:2 by weight (epoxy resin (A+B):sand), until a uniform epoxy mortar is formed.
Creation of a smooth final surface
DUROFLOOR is applied by being spread with a notched trowel at a thickness of 2-3 mm.
DUROFLOOR (A+B) consumption: approx. 0.6 kg/m²/mm.
Quartz sand consumption: approx. 1.2 kg/m²/mm.
To remove any air trapped in the self-leveling layer, the surface should be gone over with a special spiked roller. This inhibits the formation of bubbles.
Creation of a slip-resistant final surface
DUROFLOOR is applied by being spread with a notched trowel at a thickness of 2-3 mm.
DUROFLOOR (A+B) consumption: approx. 0,6 kg/m²/mm.
Quartz sand consumption: approx. 1,2 kg/m²/mm.The still fresh coating is then sprinkled with quartz sand, grade 0,1-0.4 mm (Q35) or 0,4-0,8 mm, depending on the desired slip resistance.
Quartz sand consumption: approx. 3 kg/m².Once DUROFLOOR has hardened, loose grains are removed with a high-suction vacuum cleaner.
A coat of DUROFLOOR-R is applied as a sealing layer.
Consumption of sealing layer: 400-600 g/m².
Application of DUROFLOOR 11
Mixing of DUROFLOOR 11 components
Components A (resin) and B (hardener) are packed in two separate containers, having the correct predetermined mixing ratio by weight. At first, component A must be stirred well and poured into a clean container. Then, the entire content of component B is added to component A under continuous stirring. The two components should be mixed for about 5 minutes with a low speed mixer (300 rpm). It is important to stir the mixture thoroughly near the sides and bottom of the container, to achieve uniform dispersion of the hardener.
If DUROFLOOR 11 is to be used as a self-leveling epoxy flooring, quartz sand with 0.1-0.4 mm particle size (or M32) is gradually added to the mixture under continuous stirring, in the ratio 1:1 by weight [epoxy resin (A+B):sand], until a uniform epoxy mortar is formed.
Creation of Self-leveling flooring – Smooth final surface
The epoxy mortar is poured on the floor and spread (dragged) at a thickness of 2-3 mm, using a notched trowel.
Consumption of DUROFLOOR 11 (A+B): 0.85 kg/m²/mm.
Consumption of quartz sand: 0.85 kg/m²/mm.
The self-leveling layer should be rolled with a special spiked roller, to help entrapped air escape, and thus avoid bubbles.
Creation of Self-leveling flooring – Slip-resistant final surface
At first, the epoxy mortar is applied in the same way as in the smooth surface case.
While the layer is still fresh, quartz sand is broadcast (0.1-0.4 mm or 0.4-0.8 mm particle size, depending on the required anti-slip effect.)
Consumption of quartz sand: approx. 3 kg/m².
After DUROFLOOR 11 has hardened, any loose grains should be removed with a high suction vacuum cleaner.
Finally, a finishing sealing layer of DUROFLOOR-11 (A+B) is applied by roller.
Consumption: 400-600 g/m².
Creation of Brushable coating – Smooth final surface
DUROFLOOR 11 (A+B) is applied by roller in two layers. The second layer is applied after the first one has dried, but within 24 hours.
Consumption: Approx. 250-300 g/m²/layer.
Creation of Brushable coating – Slip-resistant final surface
DUROFLOOR 11 (A+B) is applied by roller in one layer.
Consumption: approx. 250-300 g/m².
While the layer is still fresh, quartz sand is broadcast (0.1-0.4 mm or 0.4-0.8 mm particle-size, depending on the desired anti-slip effect).
Consumption of quartz sand: approx. 3 kg/m².
After DUROFLOOR 11 has hardened, any loose grains should be removed with a vacuum cleaner.
Finally, a finishing layer of DUROFLOOR-11 (A+B) is brushed.
Consumption: 400-600 g/m².
IV. REMARKS
The quality of the concrete of the floor must be at least C20/25 (minimum cement content 350 kg/m³).
In case that the substrate is wet, its preparation should take place according to the technical solution “PREPARATION OF FLOORS THAT ARE WET FOR THE APPLICATION OF EPOXY FLOORINGS”.
Working time of epoxy systems decreases when ambient temperature rises.
Bonding between successive layers may be severely affected by the intervention of moisture or dirt between them.
Epoxy layers should be protected from moisture for 4-6 hours after application. Moisture may whiten the surface or/and make it sticky. It may also disturb hardening. Faded or sticky layers in parts of the surface should be removed by grinding or milling and laid again.
In case that longer time than predicted interferes between the application of successive layers or in case that old floors are going to be laid again, the surface should be thoroughly cleaned and ground before application of the new layer.
In case DUROFLOOR will be used on vertical or inclined surfaces epoxy flow regulator should be added in a percentage of 0,5% by weight.
Before application, study the safety advice mentioned on the products’ labels.
