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SSPC-TU 10 December 1, 2002 Editorial Revisions November 1, 2004

SSPC/PCSI

JOINT TECHNOLOGY UPDATE No. 10


Procedures For Applying Thick Film Coatings and Surfacings Over Concrete Floors
This joint technology update was developed by the SSPC Unit Committee C.7.1 on Concrete Coatings and Surfacings with the assistance of members of the Polymer Coatings and Surfacing Institute (PCSI) who joined the SSPC committee and participated in the consensus review process. SSPC-SP 12/NACE No. 5 Surface Preparation and Cleaning of Metals by Waterjetting Prior to Recoating SSPC-SP 13/NACE No. 6 Surface Preparation of Concrete 2.2 INTERNATIONAL CONCRETE REPAIR INSTITUTE STANDARDS (ICRI)2 Guideline No. 03730 Guide for Surface Preparation of Deteriorated Concrete Resulting from Reinforcing Steel Corrosion Guide for Selecting Application Methods for the Repair of Concrete Surfaces Selecting and Specifying Concrete Surface Preparation for Sealers, Coatings, and Polymer Overlays Guide for Selecting and Specifying Materials for Repair of Concrete Surfaces

1. Scope and Description


This Technology Update discusses techniques and procedures to enhance performance of concrete oors by use of resinous systems greater than 20 mils. Flooring systems covered by this TU include: Thick lm systems (>500m), selfleveling systems, slurry systems, broadcast systems, mortar systems, fabric-reinforced systems, spray applied systems, and non-waterproong and underlayment membranes. Thinlm coatings (<500 m) and sealers, terrazzo ooring, membrane systems designed for waterproong, and primary and secondary containment systems are beyond the scope of this technology update. The technology update outlines techniques and procedures, with additional specic details provided in the appendices. Appendix A provides background information and requirements for the concrete substrate to which the surfacing is applied. Appendix B provides detailed information on the techniques and procedures described below. The Technology Update is intended for use by owners, applicators, and others in the coatings and surfacings industry. It addresses the unique application properties of coating and surfacing concrete oors, and should not be used for other purposes.

Guideline No. 03731

Guideline No. 03732

Guideline No. 03733

2.3 AMERICAN CONCRETE INSTITUTE STANDARDS (ACI)3

ACI 201.1R-92 ACI 201.2R-01 ACI 364.1R-94 ACI 546R-96

Guide for Making a Condition Survey of Concrete in Service Guide to Durable Concrete Guide for Evaluation of Concrete Structures Prior to Rehabilitation Concrete Repair Guide

2. Referenced Standards and Publications


2.1 SSPC STANDARDS AND JOINT STANDARDS1 SSPC-AB 1 SSPC-AB 2 Mineral and Slag Abrasives Cleanliness of Recycled Ferrous Metallic Abrasives SSPC-TU 2/NACE 6G197 Design, Installation, and Maintenance of Coating Systems for Concrete Used in Secondary Containment
1 2 3

2.4 AMERICAN SOCIETY FOR TESTING AND MATERIALS STANDARDS (ASTM)4 ASTM D 4260 ASTM D 4262 Standard Practice for Acid Etching Concrete Standard Test Method for pH of Chemically Cleaned or Etched Concrete Surfaces

NACE standards are available from NACE International, 1440 South Creek, Houston, TX 77084-4906, or from http://www.nace.org. International Concrete Repair Institute, (ICRI), 1323 Shepard Drive, Suite D, Sterling, VA 21064. (http://www.icri.org,) American Concrete Institute (ACI), P.O. Box 9094, Farmington Hills, MI 488333 (http://www.aci-int.org)

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ASTM D 4541

CONCRETE REPAIR MANUAL


Standard Test Method for Pull Off Strength of Coatings Using Portable Adhesion Testers Standard Guide for Painting Inspectors (Concrete and Masonry Substrates) Standard Practices for Determining Moisture-Related Acceptability of Concrete Floors to Receive Moisture-Sensitive Finishes Standard Test Method for Measuring Moisture Vapor Emission Rate of Concrete Sub-oor Using Anhydrous Calcium Chloride Lap Length: The length of overlapping of steel reinforcing bars. Planarity: The general evenness of a substrate in an intended dimension. Planarity should not be confused with levelness. A sloped area, for example, should be in plane, without low or high spots, but is not level. Pozzolan: A siliceous or siliceous and aluminous material, which in itself possesses little or no cementitious value but will, in a nely divided form, and in the presence of moisture, chemically react with calcium hydroxide at ordinary temperatures to form compounds possessing cementitious properties. (FCC) Recoat Time: The amount of time required for a coating, slurry or mortar to dry or cure before a subsequent coat can be applied successfully. Slump: A measure of the consistency of freshly mixed concrete, mortar, or stucco equal to the subsidence measured for the nearest 1/4 inch (6 mm) of the molded specimen immediately after removing the slump cone. (FCC) Slurry Floor: Generally 100% solids or zero VOC chemically cured resins, incorporating use of inert llers or powders, producing a owable, but not necessarily self-leveling mixture. Slurry oor materials are usually troweled to the thickness of the largest aggregate in the material. Resin: General term applied to a wide variety of polymeric products, which may be natural or synthetic. They may vary widely in color. In a broad sense, this term is used to designate any polymer that is a basic binder material for coatings and plastics. Self-Leveling Flooring: Resinous or polymer-cementitious based materials that tend to ow out when applied over a oor, seeking its own level. Self-leveling systems generally require built-up termination strips as opposed to key-in terminations for stopping points. Skim Coat: A thin layer of resin- or cement-based mortar used to smooth surface irregularities. Usually edges are feather-edged without the use of keyed terminations. Sloping Correction: 1) An adjustment applied to a distance measured on a slope to reduce it to a horizontal distance between the vertical lines through its end points. 2) The process of installing a given pitch to a surface. Soluble Alkali Ions: Substances that form charged hydroxide bases that dissolve in water.

ASTM D 6237

ASTM E 1907

ASTM F 1869

3. Denitions

Bleeding: The autogenous ow of mixing water within, or its emergence from, newly placed concrete or mortar as caused by the settlement of the solid materials within the mass. Also called water gain. (FCC) Broadcast Flooring: Usually neat (unlled) resins or slurries (aggregate lled) applied over a oor into which aggregate is blown by specialized equipment or thrown by hand, in a raining fashion, into the wet, uncured matrix and allowed to cure. Broadcast to Saturation: Aggregate broadcast into a wet matrix until the surface does not show wetness of the resinous layers below. Carbonation: Reaction between carbon dioxide and a hydroxide or oxide to form a carbonate, especially in cement paste, mortar, or concrete. The reaction with calcium compounds to produce calcium carbonate. (FCC) Capillary space: Microscopic channels on concrete small enough to draw liquid water through to be adsorbed on the inner surface. (FCC) Hydration (of Cement): The reaction of water with the calcium silicate, aluminate, or aluminum/ferrite components of ne Portland cement grains necessary for the setting and curing of concrete. Hydration results in the formation of calcium hydroxide and colloidal gels that occupy a larger volume than the original cement. Keyed (Key in): The process of removing the concrete substrate in order to create a durable termination border for a uidapplied ooring system.

4 ASTM International, 100 Barr Harbor Drive, West Cohshohocken, PA 19428-2959.(http://www.astm.org). 5 Denitions followed by (FCC) were taken from Fundamentals of Coating Concrete. The remaining denitions were developed by the SSPC Committee on Thick Film Coatings and Surfacings for Concrete, and are proposed as additions to the next revision of the SSPC Protective Coatings Glossary.

PROCEDURES FOR APPLYING THICK FILM COATINGS AND SURFACINGS OVER CONCRETE FLOORS
Tie-In: In an installation sequence, the joining of additional material to material already placed.

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4. Pre-Application Procedures
4.1 Condition Surveys: Accurate and thorough condition surveys should be performed by experienced and qualied rms or personnel prior to specication preparation. Surveys should be carried out according to referenced standards, including but not limited to ACI 201.1R-92 and ICRI Guideline 03732. Appendix A provides background information about characteristics of concrete designed for resinous oor coating application. 4.2 General Concrete Substrate Requirements: Proper design and placement of the underlying concrete are essential to the proper performance of any resinous surfacing system. Appendix A addresses critical issues that should be considered in the composite system of concrete and its surfacing, but is not all-inclusive. Detailed concrete and concrete substrate requirements are discussed at length by ACI 364.1R-94, ACI 201.2R-01, ACI 546R-96; ICRI Guidelines 03730, 03731 and 03732; and The Fundamentals of Cleaning and Coating Concrete, as well as a host of other standards and publications.

is required but no method for extraction and analysis of test results is specied or stated by the owner, agreement between contracting parties on acceptable methods of testing for soluble salt contamination should be reached prior to starting the job, in a manner acceptable to the surfacing manufacturer. 5.5 All surface imperfections should be repaired before surfacing. Repair materials and methods should comply with specications and/or manufacturers instructions. Generally, surface repairs are made with mortars of the same or similar resin bases as the oor surfacing to be placed. For example, epoxy mortars should be used for substrate repair over which an epoxy surfacing is to be applied; urethane mortars where urethane ooring will be applied; vinyl ester mortar where vinyl ester ooring will be applied, etc. As an alternative, polymer modied concrete can be used for repairs based upon manufacturers recommendations. Appendices B.3 and B.5 provide information on repair procedures, as does ICRI Guideline 03733. 5.6 The concrete surfaces to which repair material will be applied should be sound and solid, free of dust, dirt, greases, and oils. Appendix B.4 provides information on removal of oil and grease. 5.7 Surface Prole: Surfacings and coatings generally form a bond through mechanical attachment during the curing process. A proled substrate surface will gain maximum adhesion. ICRI Guideline 03732 provides comprehensive, informative guideline tools that are useful in determining required proling methods. Plastic replicas of typical surfaces produced by these methods are useful in correlating specied prole to that which is produced or required in the eld. Optimum prole is required to produce proper adhesion and performance of coatings and surfacings; too little or too much substrate prole may be detrimental to performance of a specic overlay system. See Appendices B.8 and B.9 as well as SSPC-SP 13/NACE No. 6 for additional details on surface preparation of concrete. 5.8 Masking and Protection: Surfaces adjoining or adjacent to the area being nished that are not intended to be coated or surfaced should be protected from trowel, power trowel, roller spatter, overspray and other misplacement of materials, as well as from dirt, dust or debris generated by the application operation (see Appendix B.11.1).

5. General Surface Preparation


5.1. Treatment for Alkali Silica Reaction: Sections of surfaces with unacceptable levels of Alkali Silica Reaction (ASR) should be treated either by application of a mitigating surface treatment approved by the surfacing manufacturer or by removal and replacement according to specications or using methods as described in ICRI 03730. See Appendices A.2.2.1 and B.2.1 for discussion of ASR and remediation procedures. 5.2 Moisture Vapor Transmission Rate: If the moisture vapor transmission rate exceeds 3 lbs per 1,000 ft2 in 24 hours as tested in accordance with ASTM F 1869 or E 1907 or exceeds the minimum moisture levels recommended by the surfacings manufacturer, coatings or surfacings should not be applied until moisture levels meet required limits. If the project schedule must be expedited, moisture levels may be adequately reduced by various commercial surface treatments. (See Appendices A.2.2.2 and B.2.2 for discussion of MVT and its mitigation.) 5.3 Following rehabilitative treatments, the surface should be retested in accordance with ASTM F 1869 or ASTM E 1907. 5.4 The surface should be checked for the presence of chlorides, sulfates, and other soluble salts in a manner acceptable to the owner or surfacing manufacturer. See Appendix B.2.3 for more details. Soluble salt samples used for testing should be extracted and analyzed according to procedures established in the procurement documents or per the coating manufacturers recommendations. If soluble salt removal

6. Application of Thick Film Coatings and Surfacings


6.1 Pre-Application Procedures: The work area should be checked to ensure environmental conditions for application are within specications, that the work area layout facilitates ease of application, that trafc control procedures are in place, and that adequate lighting is provided (see Appendix B.10.4). 6.2 Mixing: Most resins (unless mixed by an application unit) and aggregate blends should be mixed in accordance with

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specications and the surfacing manufacturers requirements. See Appendix B 11.2 for more detail. 6.3 Priming: Most manufacturers oor coating and surfacing systems require use of primers to enhance adhesion of the system to the prepared substrate and to minimize outgassing, the release of air from concrete as concrete temperature rises (see Appendix B.11.3). 6.4 Examination for Contaminants: The surface should be inspected for other contaminants which may have formed during or following cure, such as dirt, dust and other forms of debris, as well as for oils or other substances which may have collected on the surface. Depending upon the facility or operation, the ongoing processes may generate dust, dirt, or oily mists that may collect on a cured surface. People may walk over cured or uncured surfaces, especially after applicators leave the project, tracking contaminants on the surface. Detection and removal of contaminants prior to next application is required for adhesion. Under certain conditions epoxy primers or intermediate coats may develop amine blush, which must be removed prior to application of subsequent coatings or surfacings. Inspection for and removal of all contaminants prior to any subsequent application of coatings or surfacings is necessary for their proper adhesion. See Appendix B. 11.4 for more detail. 6.5 General Application Techniques: Application idiosyncrasies of specic coating and surfacing types are detailed in Appendix B.12. Appendix B.10.5 describes some of the specialized application equipment used for application of surfacing materials. 6.5 Recoat Time: The recommended recoat time for application of the next coating or surfacing layer should be strictly observed. Some systems require immediate application of the next material to be installed directly into wet primer. Others vary by time and temperature, and still others require the primer to be cured. Specications and manufacturers data sheets and application instructions should be consulted for specic direction. 6.6 Application of Aggregate (if required): Slip resistance is generally attained by adding specically sized or graded aggregates such as aluminum oxide, garnet, steel, silica or polypropylene beads to the nal nish. Thicker ooring systems may utilize other methods that will be described in the following sections. The degree of slip-resistant texture is best chosen by the user. The specier and applicator are cautioned against making nal texture selection for the user. Both specier and applicator, however, can work together to provide submitted samples of texture to the owner or user for nal approval and selection (see Appendix B.12.2).

7. Post Application Procedures


7.1 Cleanup: After application, the project area should be cleaned to a broom-clean condition, or to the condition required by the contract specication. All trash and construction debris should be properly disposed off-site or in designated disposal areas. All masking and protection should be removed (see Appendix B.14.1). 7.2 Touch up: Any coating or surfacing irregularities discovered after masking and protection have been removed should be touched up according to repair procedures approved by the owners representative (see Appendix B.14.2). 7.3 Tools, equipment, and materials: All equipment, tools and unused materials should be removed from the site (see Appendix B.14.3). 7.4 Protection: If required by specication or agreement, the oor should be protected as specied or with appropriate protection material such as plywood or composite board with taped joints, laid over polyethylene sheets (see Appendix B.14.5).

8. Inspection
8.1 Qualied, full time inspection by the owners inspector or a third-party inspector should be performed from job-start to job-completion, especially during preparation and application operations, to provide a systematic, efcient quality control procedure by which to assist the owner and contractor in meeting specied and manufacturers requirements. Inspections and stop points are best established prior to beginning the installation. Positive results gained by qualied, full time inspection cannot be overemphasized, and is deserving of greater detail beyond the scope of this document. For the purposes of this document, inspection should be continuous, ensuring prerequisite requirements of operations are carried out completely, tested and results recorded according to specications, manufacturers requirements and as suggested by this technology update. 8.2 Before nal cleanup, inspect the project for deviations in specications. Decient work should be corrected in accordance with repair procedures as approved by the owners representative. The following is a list of qualities or properties that are dened and agreed upon prior to installation and should be inspected in the course of application and after completion : Uniform color Gloss Texture and degree of slip resistance Straightness and neatness of termination lines Planarity of oor

PROCEDURES FOR APPLYING THICK FILM COATINGS AND SURFACINGS OVER CONCRETE FLOORS
Depressions or humps in sloping runs which could affect liquid ow Smooth transitions at oor and trench drains Smooth nishes at cove radii, internal and external corners Smooth transitions at in-oor terminations Smooth transitions at intersections of adjacent oor surfaces Full application and nished edges of sealants Spatter of cured and uncured resinous materials on surfaces not being coated

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8.3 Final Inspection. After nal clean up, and any preliminary deciency remediation, reinspect according to procedures described in this section.

9. Disclaimer
9.1 This technology update is for information purposes only. It is neither a standard nor a recommended practice. While every precaution is taken to ensure that all information furnished in SSPC technology updates is as accurate, complete, and useful as possible, SSPC cannot assume responsibility nor incur any obligation resulting from the use of any materials, coatings, or methods specied herein, or of the technology update itself. 9.2 This technology update does not attempt to address problems concerning safety associated with its use. The user of this specication, as well as the user of all products or practices described herein, is responsible for instituting appropriate health and safety practices and for ensuring compliance with all governmental regulations.

10. References
Farney, James A. and Kosmatka, Steven H. Diagnosis and Control of Alkali-Aggregate Reaction in Concrete. Skokie, IL, Portland Cement Association 1997: ISBN 0-89132-146-0. The Fundamentals of Cleaning and Coating Concrete. Pittsburgh, PA, 2001: SSPC - The Society for Protective Coatings. SSPC 01-10, ISBN 1-889060-61-5. The Inspection of Coatings and Linings. Pittsburgh, PA, 2003: SSPC - The Society for Protective Coatings. SSPC 03-14, ISBN 1-889060-75-5.

Appendix A: Background Information


A.1 General Concrete Substrate Requirements Detailed concrete and concrete substrate requirements are discussed at length in ACI 364.1R-94, ACI 201.2R-92, ACI 546R-96; ICRI Guidelines 03730, 03731 and 03732; and The Fundamentals of Cleaning and Coating Concrete, as well as a host of other standards and publications. Although the

enormity of the subject matter could easily command several sets of specic documents, the intent of this document and this section is to provide the owner, specier, manufacturer, contractor, inspector and other interested parties with concise, pertinent information and data as they generally relate to coatings and surfacings applied over concrete oors. It is important for the reader to understand that this document only addresses critical, yet not all-inclusive, issues that should be considered in the composite system of concrete and its surfacing. Concrete is mainly a mixture of Portland cement, water, and mineral aggregate, usually sand and gravel. Sometimes additives are used such as y ash and pozzolans. The mixture cures and hardens by hydration. Water in the mix combines chemically with the cement to bind the aggregate into the rigid mass known as concrete. Although properly formulated and cured concrete is strong and rigid, it can be attacked both physically and chemically. Physical attack usually results in cracking and spalling. Concrete is very strong in compression but relatively weak in tension. It can and often does crack. Concrete is also fairly porous and subject to osmotic and capillary forces that absorb and release water. Absorbed water can freeze within the concrete and cause spalling and cracking. Strength-gain, wear-resistance, and shrinkage properties of every concrete mix design are affected by the water-tocementitious (w/c) ratio, normally expressed as the weight (pounds) of mixing water per weight (pounds) of cement. Concrete with a lower water-cement ratio gains more strength than concrete with a greater one, but such low ratios may be difcult to place and consolidate properly because of the stiffness of the mix. Chemical admixtures (water reducers) are often used to increase workability of the concrete while keeping the water-cement ratio low. High water-cement ratios increase shrinkage cracking and reduce surface wear resistance and compressive strength. Approximately 0.19 lb of water for each 1 lb of cement is required for complete cement hydration. Roughly twice that ratio, or 0.38 lb of water per each 1 lb of cement, is required for mixing, because additional water is absorbed on gel pore surfaces and the cement particles must all be wetted. More water may be added to enhance workability when placing concrete, but any amount in excess of 0.38 lb per lb of cement is not required for the hydration process and may eventually leave the concrete via evaporation or as bleed water. Such excess water increases shrinkage and contributes to the formation of cracks and continuous capillaries in the hardened concrete paste. These capillaries become channels for moisture movement and for intrusive and harmful chemical solutions after the cured concrete is placed in service. Wet curing will minimize incidence of these capillary channels. A.1.1 Designing oors for resinous oor systems: While concrete slabs should be placed in accordance with standard ACI practices, it is equally important that the concrete be designed to accommodate the intended end use. A water-cured, light steel troweled nish is most suitable for subsequent application of resinous systems. Any placement method, however, that

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gel, which absorbs a signicant quantity of water. Expansion of the amorphous silica gel creates internal pressures within the concrete leading to paste fractures and deterioration of the concrete. ASR is manifested by cracking followed by spalling, strength loss, and disintegration of the concrete matrix, which sometimes causes pop outs, fragments of concrete that break away leaving a shallow, conical depression. When the amount of alkali is greater than the amount of reactive siliceous aggregates the alkali silica gel may absorb water and swell, causing expansion soon after curing. This is frequently manifested after one or more years. A.2.2.2 Moisture Vapor Transmission (MVT): Water or liquid moves through concrete through small pores, or capillaries, in the form of vapor, always from an environment of high vapor pressure to low vapor pressure. Vapor pressure combines the effects of temperature and humidity. In general, moisture migrates from warm, humid conditions to cool dry conditions. If the environment below a concrete slab is continuously wet, capillary action will pull liquid from below the slab into the slab, but moisture most frequently moves in concrete as a vapor driven by the differential in vapor pressure. Providing drainage under the concrete slab helps to reduce the source of water below it. Use of vapor barriers is required to eliminate moisture sources from below the slab. The vapor barrier should meet the requirements of ASTM E 1745, with a permeability rating of 0.30 or less. Placement of this moisture barrier must be continuous and in compliance with ACI 504. ACI 302 recommends a two-inch layer of granular self-draining compactable ll above the vapor barrier. If this recommended practice is followed, extraordinary measures must be taken to keep this ll dry. If water is allowed to be captured within this layer, it will serve as a water reservoir under the slab. In most cases, it is more advantageous to pour the concrete directly onto the moisture vapor barrier, and use moisture curing techniques to prevent drying shrinkage cracking. As vapor is driven through the concrete, soluble alkali ions are transmitted with it and collect at the surface. When moisture cycles back into the slab, concentrating the ionic solution, crystals can form which can create enough force to disbond a resinous surfacing. If undetected, the combined phenomena of MVT and ASR will generally result in bond failure when concrete is used as a substrate over which resinous surfacings are applied. Determination of the extent of ASR deterioration and subsequent concrete substrate treatment, whether removal and replacement or in-situ rehabilitation by specic rehabilitative treatments, is best determined by qualied rms or personnel during the specication preparation process. A.2.3 Carbonation: Although naturally occurring in all atmospherically exposed concrete, the ne surface crazing and softening of concrete upper surfaces particularly manifests itself when the surface is exposed to increased levels of airborne carbon dioxide during the hardening stage. Exhaust from direct-red heaters commonly used during cold weather

maximizes surface strength is acceptable. Minimal nishing normally produces the strongest surface. Wet-cured concrete (ACI 308-92, Chapter 2), by use of burlap and waterproof cover, is preferred over use of curing compounds. Although excellent curing compounds are available, proper wet curing facilitates hydration without potential for chemical interference of the curing compound with subsequent resinous system application. New concrete (Type 1 Portland cement) is designed to develop about 80% of its design strength in 7 days and nearly all of its overall strength in 28 days. Excess residual or free water not used in the hydration process of cement will continue to migrate out of the concrete until it reaches equilibrium with its environment. There is a potential problem in the placement of resinous systems over new concrete even after 28 days if excess water is still present, if the excess water is continuing to move from the concrete to the environment above the slab. It is the movement of moisture vapor within the slabnot the total quantity of moisture within the slabthat creates subsequent problems with non-permeable oor surfacings. An effective concrete substrate must be low in permeability and high in density. The general mix design shown in Table A.1 is an example of a mixture that will yield a suitable substrate. Tensile bond strength of a concrete substrate is important in concrete design. Tensile strength of concrete is approximately 10% of its compressive strength.Most resinous surfacings manufacturers prefer minimum tensile bond strength to be 350 psi as measured per ASTM D 4541. A.2 Surface Preparation Considerations for Concrete Substrates A.2.1 Chemical Attack: Chemical attack can occur because concrete is alkaline and chemically reactive. It can be attacked by mineral acids; some alkalis; numerous salt solutions; and organic acids such as fermenting liquids, sugars, and animal oils. Corrosive solutions penetrating to the steel reinforcing may be particularly destructive because the large displacement of corrosion products of steel can cause cracking and spalling of concrete. A.2.2 Alkali Silica Reaction (ASR) and Moisture Vapor Transmission (MVT): ASR and MVT are major causes for failure of coatings and surfacings applied to on-grade or below-grade concrete. Both ASR and MVT are discussed together in this subsection, as continuing research seems to bear out a homogeneous relationship between the two phenomena. Evolving data suggests moisture vapor to be the transmission force that drives greater deleterious effects of ASR toward the concrete surface and the bond line of resinous surfacings, resulting in high potential for adhesion loss. A.2.2.1 Alkali-Silica reaction (ASR) occurs in concrete when soluble alkali ions such as sodium and potassium react with chemically active forms of silica (usually present in the sand or gravel aggregate). The reaction produces an expansive

PROCEDURES FOR APPLYING THICK FILM COATINGS AND SURFACINGS OVER CONCRETE FLOORS
increases the carbon dioxide levels, and is a leading, though not the only, cause of carbonation. Generally, carbonated concrete surfaces are soft or powdery, with insufcient tensile strength to maintain substrate bonding properties required for surfacing adhesion. Standard adhesion testing methods according to ASTM D 4541 can be used to determine concrete surface strength required by surfacing manufacturers and/or specications (see Appendix B.1). A concise discussion of carbonation can be found in the chapter entitled "Condition Assessment" in Fundamentals of Cleaning and Coating Concrete). A.3 Amine Blush Following the cure of primers and other applied layers over which additional coatings or surfacings will be installed, the surfaces should be inspected for the presence of amine blush and other contaminants that could prevent or inhibit adhesion and contribute to intercoat delamination. Amine blush manifests itself as an oily, greasy, waxlike residue over the surface of a cured coating or surfacing, caused by rapid solvent evaporation or the reaction of an amine component, generally in the presence of moisture or high humidity and/or in low temperatures. Specically, an amine co-reactant in a coating or surfacing reacts with carbon dioxide and water to form an amine carbonate, which can, and usually does, adversely affect adhesion of subsequent coating or surfacing applications. Recognition and removal of amine blush is critical for successful installations. Manufacturers do not uniformly indicate on system data sheets or application instructions product susceptibility to amine blush or precautions to be taken if their specic products are susceptible to amine blush. Product usersowners, speciers, contractors and inspectorsshould contact the manufacturers Technical Service Department directly for clarication if precautions about amine blush are not published. Conditions of high humidity or moisture or low or declining temperatures during cure, and especially the combination of high humidity or moisture and low or declining temperatures during cure, present high potential for blush formation. In colder climates, isolated areas away from heat, espe-

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cially near exterior walls may develop amine blush, while other areas may not. Close inspection of the entire area is recommended, paying particular heed to susceptible isolated areas. Air-conditioned areas may also present environments suitable for formation of amine blush. Advanced stages of amine blush formation are easier to detect than less advanced formations. At this writing, no recognized standard or test method exists for detection of amine blush, limiting inspection to subjective powers of visual observation and touch. In its most advanced stage of formation, amine blush is evidenced by a milky-white opalescence on a surface, feeling very oily or greasy to a point where the surface is slippery. Initial appearance might indicate to the observer that the coating or surfacing did not cure. Less advanced formation stages may not exhibit a milky-white opalescence, but may present only a slight oily or greasy residue, difcult to feel. This stage of formation is the one that creates the most difcult problem, as subjective discovery or recognition of the phenomenon may be overlooked or missed. Amine blush can be removed by detergent washing. Solvent washing is not recommended as residues may leave chloride salts and other bond-inhibiting contaminants on the surface. Blush is best removed by use of a oor scrubber utilizing detergent and warm water, followed by thoroughly rinsing the scrubbed surface. Allow treated surface to dry completely, and then reinspect the surface. Rewash, rinse and allow drying if blush is detected. Then reinspect. Usually amine blushing is easily removed with a single wash and rinse. During winter months in colder climates, or at any time or location where conditions may be likely to produce amine blush, it may be appropriate to treat the surface according to Appendix B.11.4, as if amine blushing is present, but undetected.

Appendix B: Detailed Preparation and Application Procedures


B.1 Condition Assessment of Existing Substrate The substrate receiving the surfacing should be examined carefully prior to specication preparation. Accurate and thorough condition surveys conducted by experienced and qualied professional rms or personnel are recommended prior

TABLE A.1 EXAMPLE OF GENERAL MIX DESIGN Cementitious Content (minimum) Water-Cement Ratio (by weight) Maximum Coarse Aggregate Size Air content Slump (without high range water reducers) Slump (with high range water reducers) Compressive Strength (28 days) Permeability Cement options Water 517 lbs/cubic yard 0.40-0.45 1-1/2 inches 4-6% < 3 inches 6-9 inches 5,000 psig low

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manufacturers requirements or as described in Section B.3. For at least two weeks prior to application, environmental conditions should be representative of normal operating conditions at the facility in order to allow the concrete substrate to reach equilibrium. Any irregularities which do not meet the specications should be brought immediately to the attention of the project governing authority B.2 Surface Treatments B.2.1 ASR Mitigation: Alkali Aggregate Reaction (AAR), including ASR (Alkali Silica Reaction) is a major cause of the failure of coatings and surfacing over concrete, but it is not easily detected in the eld. It is best determined by recognized testing agencies equipped to perform petrographic analysis. If levels of ASR have been discovered and the condition of the substrate has been determined to be treatable by removal and replacement of specied sections of concrete substrate, those sections should be removed and replaced according to contract specications or using the methods described below. If ASR mitigation has been determined to be treatable by mitigating surface treatment techniques approved by the surfacing manufacturer, those procedures should be carried out according to the contract specication or the surfacing manufacturers instructions. B.2.2 MVT Mitigation: Moisture vapor transmission, as dened in Appendix A, must be controlled in order to prevent subsequent bond problems with an installed impermeable coating or ooring system. The moisture vapor transmission rate should be determined in accordance with ASTM F 1869 or E 1907. If the project schedule must be expedited, moisture levels may be adequately reduced by various commercial surface treatments, which should be used in accordance with specications or as approved by the owner and the surfacings manufacturer. The surface should be retested in accordance with ASTM F 1869 or ASTM E 1907 following rehabilitative treatments. If the moisture vapor transmission rate exceeds 3 lbs/1,000 ft2/24 hours (15Kg/100m2/24 hours) as tested in accordance with ASTM F 1869 or ASTM E 1907, or exceeds the minimum moisture levels recommended by the surfacings manufacturer, do not apply coatings or surfacings until moisture levels meet required limits. B.2.3 Soluble Salt Mitigation B.2.3.1 Removal: If soluble salts, such as chlorides, sulfates and nitrates, are found or suspected to be present, they should be removed or the concrete treated prior to installation of coatings or surfacings. Such removal is generally accomplished by high pressure water cleaning as described in SSPC-SP 12/NACE No. 5. Normally, High-Pressure Water Cleaning (HP-WC) performed at pressures from 34 to 70 MPa

to specication preparation. Surveys should be carried out as described in referenced standards, including but not limited to ACI 201.1R-92 and ICRI Guideline 03732. Floors should be examined for grease and oil deposits. Inspection by core testing is recommended in areas where oils or greases have extensively contaminated concrete for long periods. Cores that exhibit contamination present to a depth of 1 in (25 mm) or greater usually require removal of the contaminated concrete surface, rather than remediation techniques, to achieve a surface condition suitable for adhesion of coatings or surfacings. Determination of the best strategy for oil and grease removals should be developed during specication development, as described in Section B.4. Removal or remediation techniques may be time consuming. Developing a plan for proper treatment in the specication helps to ensure correct conditioning and timely execution. Investigate the facility operation to determine potential presence of unusual contaminants. Existing sealers, coatings or surfacings must be removed or treated in accordance with specications and surfacing manufacturers requirements. A non-laboratory eld inspection of the substrate should include: Verication of the dimensions of the substrate. Verication that the planarity and slope meet requirements and/or specications. Verication that the concrete surface strength meets the surfacing manufacturers requirements. Generally, minimum surface strength of 200 psi as measured as described in ASTM D 4541, is required for oor surfacing adhesion. A strategy should be developed for rehabilitation or removal (Section B.3) of areas of inadequate surface strength in accordance with manufacturer requirements. Determination of the presence of chlorides, sulfates and other soluble salts in accordance with the procurement documents or the surfacing manufacturers guidelines. Contaminating salts are frequently present in plants and other facilities where chemicals and solvents are used. Contaminants should be removed in accordance with manufacturers recommendations or as described in Sections B.2. Determination of the presence of existing sealers, coatings or surfacings. The treatment strategy should be in accordance with specications and manufacturers requirements. Determination of the moisture vapor transmission rate in accordance with ASTM F 1869 or E 1907. Determination of the presence of Alkali Aggregate Reaction (see Section B.2.1). Both static and moving cracks should be identied and treated in accordance with the surfacing system manufacturers requirements or as described in Section B.5. Spalls, pop-outs, aggregated surfaces and other imperfections should be noted and treatment strategies developed as described in the surfacing

PROCEDURES FOR APPLYING THICK FILM COATINGS AND SURFACINGS OVER CONCRETE FLOORS
(5,000 - 10,000 psi) is adequate for salt removal. Commercial decontaminating treatments are available which reduce amounts of required water consumption and pressure. B.2.3.2 Testing: Contaminating salts are frequently present under existing conditions in plants and other facilities where chemicals and solvents are used. Current industry standards do not specically address extraction and analysis of soluble salts in concrete, however data is evolving. Soluble salts and other similar contaminants should be removed according to specication or as required by the surfacing manufacturer. B.3 Repair of Surface Imperfections Dings, holes and surface imperfections (other than cracks) that are less than 1/2 inch in depth and 2 inches in diameter should be lled with the same or similar resin as the coating or surfacing, compounded into a mortar or gel, or llers recommended by the surfacing manufacturer. Holes, spalls and other surface imperfections that are greater than 1/2 inch in depth and 2 inches in diameter, where steel reinforcing IS NOT exposed, should be prepared so that the repair area is squared up and shouldered. Terminations of all repairs should be extended to a vertical abutment. Flashpatched edges, or edges terminated at a skim coat level on top of the concrete substrate, are not recommended. Sound out the area surrounding the spall or hole by tapping with a hammer on the surrounding concrete in all directions extending from the repair area, listening for hollow sounds. The limits of hollow sounds around the perimeter of repair area indicate the limits of unsound concrete substrate. The perimeter area of the unsound concrete should be marked with chalk. The repair area should be marked by chalking out a rectangle or square perimeter that includes the entire unsound area. Refer to layout as illustrated in ICRI Guideline 03730, Edge and Surface Conditioning of Concrete, Item 9. The marked perimeter should be sawcut to a minimum depth of 5/8 in. (12 mm) or to a depth recommended by the repair product manufacturer. Edge shoulders should be perpendicular to the substrate surface, as illustrated in ICRI Guideline 03730, Item 8. The repair area, including edges, should be vacuum cleaned and free of oils and greases. The repair material to be used should be compatible with the surfacing manufacturers ooring system. Repair methods should comply with specications and/or the manufacturers instructions. Holes, spalls and other surface imperfections that are greater than 1/2 inch in depth and 2 inches in diameter, and where steel reinforcing IS exposed, should be repaired in accordance with ICRI Guideline 03730. Any unsound, disbonded concrete above the reinforcing steel should be removed. The extent of the unsound, disbonded concrete may be determined by sounding methods described above and by evaluating the soundness of the concrete during removal. All exposed corroded steel reinforcing bars should be undercut if exposed reinforcing steel is found to be rusted or

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otherwise corroded after initial removals are made. A minimum 3/4-inch (19 mm) clearance between exposed bars and surrounding concrete, or 1/4 inch (6 mm) larger than the largest aggregate, whichever is greater, should be maintained. Concrete removals should extend along the bars to locations where the bar is free of bond-inhibiting corrosion and is well bonded to the surrounding concrete. If corroded bars have lost signicant cross-section, and this condition is not addressed in the specications, a structural engineer should be consulted for further direction. The structural engineer may recommend full bar replacement or the addition of a supplemental bar over the affected section. If non-corroded reinforcing steel is exposed during the undercutting process, care should be taken not to damage the bars bond to the surrounding concrete. If the bond between the bar and the concrete is broken, undercutting of the bar should be required. Any reinforcement that is loose should be secured in place by tying to other secured bars or by other approved methods. All heavy corrosion and scale should be removed from the bar as necessary to promote maximum bond of replacement material, preferably by blasting with oil-free abrasive. Tightly bonded light rust buildup on the surface is not usually detrimental to the bond unless a protective coating is being applied to the bar surface. If a protective coating is to be used, surface preparation of the bar should comply with the manufacturers instructions. Supplemental replacement bars used to correct eroded bars may be mechanically spliced to old bars, or supplemental bars may be placed parallel to and approximately 3/4" (19 mm) from existing bars. Lap lengths should be determined in accordance with ACI 318. Contractors and manufacturers should exercise particular caution regarding repair or rehabilitation of reinforcing steel. Load design is outside the domain of those not licensed or qualied to fully analyze structural requirements. The repair material selected should be compatible with the surfacing manufacturers ooring system and should be installed in strict accordance with specications and repair material manufacturers requirements. Generally, surface repairs are made with mortars of the same or similar resin bases as the oor surfacing to be placed above it. The concrete surfaces surrounding areas to which repair material will be applied should be sound and solid, free of dust, dirt, greases, and oils. The repair area, including shoulders, must be vacuumcleaned, free of dust, dirt, greases, oils, and any other contaminants that may inhibit bond. The edges of decient areas that require planarity and sloping correction prior to application of surfacings should be keyed-in to terminate at square shoulders or edges without ash patching. After determining the substrate area to be corrected, chalk-lines should be snapped to outline the perimeter. The substrate should be sawcut to a depth of 1/4 inch (6 mm) or twice the thickness of the surfacing material to be installed, whichever is greater. If surfacing material is less than 1/8 inch (3 mm) thick, the kerf (the width of the saw blade) must be at least 1/8 inch (3 mm) in width. If surfacing material

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Non-structural, non-moving cracks should be routed open with a saw, grinder or concrete routing apparatus to a minimum depth of 1/2 inch (12 mm). Cracks less than 1/8 inch (3 mm) in width should be opened to at least 1/8 inch (3 mm). Cracks greater than 1/8 inch (3 mm) but less than 1/4 inch (6 mm) in width should be opened to at least 1/4 inch (6 mm) in width. Cracks 1/4 inch (6 mm) or greater should be cut on both sides of the crack, opening the crack wider than the existing width. All cracks should be vacuum cleaned to remove dust, dirt and debris. To repair the concrete and return the substrate to a monolithic surface, prepared cracks should be lled with the same or similar resin as the coating or surfacing, compounded into a mortar or gel or crack ller as recommended by the surfacing manufacturer. Structural cracking, especially that found in suspended concrete around structural members and large moving machinery, should be analyzed by qualied engineering professionals to determine the relationship of cracking to the overall construction integrity. Structural cracks may be moving or non-moving, with stabilization and treatment methods determined by engineering professionals. Non-moving cracks are generally stabilized by several methods, including providing additional support and epoxy injection. If future movement of a crack cannot be ruled out it should be treated as a moving crack. Moving cracks in stabilized concrete are generally treated as functional joints (see Section B.6). The effects of movement are controlled by the use of exible sealant systems, compression seals, and other treatments over which hard coatings and surfacings are usually not applied. Hard, inexible coatings and surfacings will not absorb movement and will reect substrate cracking, requiring functional joints or cracks acting as functional joints to be incorporated separately as part of the nished coating or surfacing system. They should not be overcoated. Irregularly-shaped moving cracks are usually straightened by completely lling the crack with an adhesive resin, usually epoxy, then making a straight sawcut between the two endpoints of the crack. Cutting a joint to a minimum depth of 1 inch (25 mm) by 1/4 inch (6 mm) wide, with the bottom of the sawcut ending above the steel reinforcing, will provide a new controlled crack plane. Topical treatments and lling of cracks by the use of exible membrane systems helps to absorb or cushion movement and mitigate substrate crack reection through an overlaid surfacing. Any topical membrane treatment should be used in strict accordance with specications and surfacing manufacturers instructions. Certain membrane systems may require placement of tape or wax bond breaker material over the crack. Usually a 1-inch (25 mm) wide bond breaker material is centered over the crack, and a 4- to 6-inch (101 to 152 mm) membrane,

is 1/8 inch (3 mm) or greater, another sawcut to a depth of 1/8 inch (3 mm) inside the perimeter should be made. The distance between the outside and inside sawcuts should be: 3 inches (76 mm) for surfacing material thickness up to 3/16 inches (5 mm); 4 inches (101 mm) for surfacing material thickness up to 3/8 inches (10 mm); For surfacing thickness greater than 5/8 inch (13 mm), the distance between the two sawcuts should be an additional 1 inch (25 mm) for each 1/8 inch (3 mm) thickness over 5/8 inch (13 mm). After the outside and inside sawcuts are made, the key is created by chipping out concrete between them, making a sloping transition that increases in depth from the inside to outside sawcuts. The prole within the substrate correction area should be created as described in ICRI Guideline 03732, and as later described in this document. The repair material selected should be compatible with the surfacing manufacturers ooring system and should be installed in strict accordance with specications and repair material manufacturers requirements. B.4 Removal of Oil and Grease Oil and grease should be removed from concrete substrates prior to subsequent surface proling and application of any other coating or surfacing materials. If concrete removal is specied or required, remove concrete according to contract specications or Section B.3. Water soluble or detergent-emulsiable contaminants should be removed by scrubbing with a detergent solution as described in ICRI Guideline No. 03732. Following the application of suitable chemical detergent solution, the surface should be scrubbed with a stiff-bristled broom, brush, or scrubbing machine. Used solution should be collected and properly disposed. The process should be repeated as necessary to achieve acceptable results. Oils and greases that are not water soluble or detergentemulsiable may be removed by use of steam. Steam should be applied over the affected area to allow oil or grease to rise to the surface. Residue should be removed and the surface should be rinsed clean. The process should be repeated until acceptable results are achieved. Some surfacing manufacturers offer oil-tolerant primers, generally applied after mitigating techniques described above. Job specications or surfacing manufacturers instructions should be followed carefully when using these primers. B.5 Repair of Cracks Cracks should be pretreated prior to application of any coating or surfacing, unless otherwise directed by specication or surfacing manufacturer. Generally, surfacing thicknesses less than 3/16 inch (5 mm) will mirror substrate cracking, even if the cracking is non-moving.

PROCEDURES FOR APPLYING THICK FILM COATINGS AND SURFACINGS OVER CONCRETE FLOORS
sometimes reinforced with berglass, is applied over the bond breaker. Other membrane systems may not require the use of bond breakers, but may require that the crack be pre-lled with a exible product prior to application of the membrane. Additional information on concrete cracking may be found in SSPC TU 2/NACE 6G197, The Fundamentals of Cleaning and Coating Concrete, and ACI 224-1 (latest revision). B.6 Preparation of Joints Joints comprise an integral part of concrete structural design, particularly for oors, providing planned, systematic details to accommodate concrete placement. They also allow for contraction during curing, expansion and contraction during temperature variations, differential settlement and crack control. It is important to be able to identify the functions of joints encountered in coatings and surfacings work, and to treat each joint in a manner that retains its full functionality. ACI 116R denes ve functional joints. Unless otherwise specied, without other special treatments, coatings and surfacings should not be placed over functional joints. Movement in functional joints generally exceeds elongation at break properties of coatings and surfacings, resulting in cracking of nished work above or in proximity of the covered joint. Existing joints should be prepared by removing existing llers, sealants or other materials prior to coating or surfacing application. Following removal of joint materials, both sides of the joint should be sawcut to create clean, bondable surfaces. The surface should be vacuum cleaned after sawcutting. Benchmarks may be created by driving nails or other devices into the center of prepared joints, along straight runs, to allow for later sawcutting and sealing following completion of nished coatings and surfacings. If the contract specication or manufacturers recommendations require joints to be covered with coatings or surfacings without other special treatments, the appropriate sealant should be installed as described in the contract specication or the surfacing manufacturers instructions. SSPC TU-2/NACE 6G197 offers substantial guidance on joint designs, and should be consulted in detail, especially for special joint treatments. Where joint width and depth are greater than 1/4 x 1/4 inch (6 x 6 mm), the depth of sealant should be one-half (1/2) the width of the joint, generally not exceeding a minimum width of 1/4 inch (6 mm) and a maximum depth of 1/2 inch (13 mm). Joint llers, such as dry sand, or commercially available backer materials, such as closed cell foam backer rods, can be used to control sealant depth. Sealant should adhere to both sides of the joint, but not to the bottom, as three-point bonding generally results in sealant failure. Bond breaking material, such as a polyethylene strip or plastic- faced electrical tape, should be placed over other backer materials to prevent adhesion. Masking tape should be placed along both sides of the joint to maintain neat, straight lines after the sealant is installed. The amount of sealant installed should ensure that the joint is full and ush with adjacent edges. Masking tape should be removed prior to joint cure. B.7 Coved Base Preparation

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Integral coved base is that part of the nished ooring system which terminates at oor edges by turning up abutments, such as walls, equipment pads and other vertical surfaces, usually from 4 - 8 inches in height (102 - 203 mm). It can vary from a simple 1 inch (25 mm) spoon-cove to a wainscot application covering the lower part or all of a wall. Vertical substrates to which coved base may be applied may be constructed of concrete, cement masonry units, glazed masonry units, brick, wood or drywall. Care must be exercised to ensure that the structure of vertical substrate is sound, solid, and stable. The surface condition of a vertical substrate, especially drywall or wood, should be inspected for soundness and compatibility with the materials to be applied. Deteriorated drywall or wood substrate sections may require removal and replacement with more compatible substrate materials such as cement board. Base design must be clear and understood to determine extent of proper preparation and termination techniques. Some factors that determine preparation methods include, but are not necessarily limited to: Height of the base. Existence of joints at or near wall-oor intersection. Use of metal or plastic termination strip at top of base. Use of reglet (sawcut) as top termination. Use of bullnose (rounded) top termination. Use of feathered top termination. Use of spoon-cove (radius) only. Use of splay or chamfered base. Unless otherwise specied, the top of the coved base should be parallel to the elevation of the nished oor, especially where the oors are pitched or sloped, or the nished system may have an irregular appearance. If the base is to be applied to nished wall surfaces, careful masking and protection will be required during preparation operations to minimize damage and staining. The use of duct tape or other strongly adhesive tape may remove nished wall surfaces. Tape such as 3M Long-mask, which are designed to be removed with minimum surface pull-off, may result in minimal damage. The planarity of the base substrate should be repaired and patched with appropriate resinous or polymercementitious materials as specied or as described in surfacing manufacturers instructions. The substrate should be prepared as discussed in Sections B.3 through B.6. Surfacings other than troweled mortar systems may require the coved base to be formed from resinous or polymer-cementitious mortar applied by trowel and then coated, tying-in the specied system at the termination of the cove or splay. When this method is used, metal or plastic termination strips placed at the toe of the cove often result in better base-oor transitions. The top of the base should be nished in straight, neat lines. Joints at wall-oor intersections may require the use of sealant to form the cove or splay to prevent cracking. Depending upon anticipated movement, other methods may be used, such as forming the cove with sealant, applying a bond breaker

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subside, surfaces should be ushed to remove reaction products and inspected for uniform roughening and removal of laitance. To obtain the required surface condition, several applications of acid may be required. Any residue should be vacuumed away and the surface should then be scrubbed with an alkaline detergent. This process should be repeated until etching debris is completely removed. The surface should then be rinsed with clean, potable water, scrubbed and vacuumed dry. Rinse water should be tested as described in ASTM D 4262. At least two pH readings for each 500 ft2 (46 m2) or portion thereof should be taken at randomly selected locations following the nal rinse but before all the rinse water has drained off the surface. The pH readings following the nal rinse should not be more than 1.0 pH lower or 2.0 points higher than the pH of the water before rinsing begins, unless otherwise specied. B.8.2 Grinding: Grinding is generally used on concrete substrates to reduce or smooth surface irregularities and to remove mineral deposits and previously applied thin lm rigid coatings, usually less of than 6 mils (150 m) thickness. Grinding does not usually produce an acceptable prole over which to apply coatings and surfacings; other methods, usually shot blasting or scarifying, are normally used subsequent to grinding treatments. Grinding may be accomplished by wet grinding or dry grinding using portable equipment ranging from small hand-held grinders to walk-behind units with multiple discs. Wet grinding minimizes or eliminates airborne dust, but produces a slurry residue. Slurry and rinse water should be collected and properly disposed. Dry grinding produces ne airborne dust, which may be controlled by use of dust control attachments. B.8.3 Abrasive Grit Blasting: Concrete oors are seldom cleaned by abrasive blasting because of the amount of dust generated in interior workspaces. While most often impractical for concrete oor substrate proling, abrasive blasting does provide the capability to produce proles ranging between ICRI Replicas CSP 2 to 4, and may also produce proles ranging from 1 to 30 mils (25 to 750 m). Blast curtains and any other containment media should be erected and in place to protect people, property and the environment during blasting operations. The selected blast media should be of a type approved by all environmental regulatory agencies. (Silica is a prohibited abrasive blast medium in many areas of the US.) The blast media should be clean and free of contaminants according to contract specications, SSPC-AB 1, or SSPC-AB 2. The size and type of blast media should be appropriate to produce the desired prole. Blast personnel should be trained and qualied to safely use abrasive blast equipment and should be fully cognizant of related environmental issues. All equipment should be properly sized and ltered to produce an efcient blast media stream, free of oil and moisture, complying with all safety regulations and requirements. The nal prepared surface should be free of dust, dirt, debris and any bond-inhibiting contaminants. B.8.4 Steel Shot Blasting: Steel shot blasting, generally referred to as shot blasting, is the proling preparation method

over the sealant, then applying resin-impregnated berglass from the top of the base to approximately 1 to 2 inches (102 to 203 mm) beyond the cove onto the oor. B.8 Establishing Surface Prole Surfacings and coatings require a proled substrate surface to gain maximum adhesion. ICRI Guideline 03732 provides comprehensive, informative guidelines and tools that are useful in determining required proling methods. Plastic replicas of typical surfaces produced by these methods are useful in correlating specied prole to that which is produced or required in the eld. After substrate surfaces have been rehabilitated to a sound condition as described in preceding sections of this document, the surface should be proled to meet the specication or the surfacing manufacturer's requirements for proper adhesion and performance of coatings and surfacings. A substrate prole that is either too low or too high may be detrimental to performance of a specic overlay system. B.8.1 Acid Etching: Acid etching is a practice used to remove weak surface laitance and some foreign materials and to produce a surface prole between 1 to 5 mils (25 to 125 m), as illustrated by ICRI Replicas CSP 1 to 3. Generally, the prole produced by acid etching is suitable for sealers and coatings with thicknesses up to 10 mils, which are outside the scope of this technology update. However, acid etching may be specied for use in special circumstances. ICRI Guideline 03732 and ASTM D 4260 describe acid etching techniques. Acid etching is a preparation technique used with diminishing regularity. Other proling methods are generally preferred and are more effective. Etching solutions are highly corrosive, and environmental considerations may require full containment and recovery of spent acid and rinsewater. Because the etching process saturates the substrate, the substrate must be allowed to dry prior to the application of most coatings, which may impede installation schedules. Acid etching is inappropriate if the concrete substrate surface is sealed with sealers or coatings. In this case, other proling methods should be used. Oil, grease, and other penetrating contaminants should be removed prior to etching. Protruding surface irregularities should be removed by mechanical means. The substrate surface should be pre-wet with water prior to etching, with any freestanding water removed. The etching solution (e.g., phosphoric or citric acid) should be prepared according to contract specications and manufacturers instructions. Hydrochloric and muriatic acids (diluted hydrochloric or sulfuric acid) leave soluble salts in the substrate and should not be used where chlorides cannot be tolerated. The etching solution should be applied uniformly over the wet surface by use of polyethylene sprinkling cans or lowpressure sprayers at the rate of 90 to 100 ft2 (8 to 9 m2) per gallon. The applied acid solution is agitated with a stiff bristle broom or power brush for ve to ten minutes and the surface is not permitted to dry. When etching solution bubbling begins to

PROCEDURES FOR APPLYING THICK FILM COATINGS AND SURFACINGS OVER CONCRETE FLOORS
most often recommended by coatings and surfacings manufacturers. Steel shot is centrifugally propelled to the substrate surface at a high velocity within a closed blast chamber that recovers and separates dust and reusable shot. The operation, when using properly maintained equipment, generally produces a minimum amount of dust, and is capable of producing proles ranging between ICRI Replicas CSP 3 and 8. Shot blasting cleans and proles concrete surfaces by removing dirt, laitance, curing compounds, sealers and other supercial contaminants. Prior to shot blasting, grease and oil that has penetrated the substrate surface should be removed. Heavy dirt, foreign matter, and other debris, such as bolts, screws and other metallic objects that could damage the shot blast equipment, should also be removed. Shot blast equipment is available in a range of sizes to provide ready access to most surfaces. Depending upon the equipment used, edges and corners may be detailed to within 1/4 inch (6 mm) of vertical surfaces. The depth of removal is controlled by shot size, machine setup, and rate of travel. As the depth of cut increases, prole will be increasingly dominated by the size and shape of coarse aggregate in the concrete. Generally, the maximum efcient depth of removal in a single pass is 1/8 inch (3 mm). Shot between S-230 and S-390 mesh is used for creating proles for most oor coatings and surfacings. Other sizes are also available. S-230 and S280 produce proles matching ICRI CSP 3. S-330 and S-390 produce proles matching ICRI CSP 5. Striping or double exposure occurs where successive passes overlap, producing striations that transmit through the coatings and surfacings applied in insufcient thickness to ll these irregularities. Any blast pattern in the substrate is usually visible through clear coatings. Trained and experienced operators can operate equipment to minimize the effects of striping, but the blast pattern will usually remain to some degree. Unless otherwise specied, coating materials should be applied as described in the manufacturer's instructions to achieve the specied thickness and surface nish, and ll the blast pattern. The work area should be cordoned off, and all personnel in the work area should wear suitable eye protection and personal protective equipment as required. All stray shot should be removed from the substrate surface prior to application of coatings and surfacings. Magnets or magnetic devices may be used to pick up stray shot. Particular attention should be paid to removing accumulated shot from joints, cracks, and holes. The surface should then be swept, vacuumed, and nally cleaned with a oor scrubber. Errant or stray shot can accumulate under equipment shrouds. B.8.4 Scarifying: Scarication is generally a dry preparation process used alone or in conjunction with other preparation methods. Scariers and related equipment are available in a large variety of types and sizes. All operate from rotary action cutters assembled on rods mounted at the perimeter of a drum rotating at high speed. This method can be used to clean concrete and remove high spots and adhesives, as well as to

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remove brittle coatings and surfacings, and to produce prole ranges matching ICRI Replicas CSP 4 through 9. Scarication, especially when using larger walk-behind units, is an aggressive preparation method that can create microcracking in the concrete substrate. The rotary action of the cutters impacting the surface at right angles fractures and pulverizes the concrete in varying degrees. Scarifying, especially with larger equipment, generally produces a striated pattern in the concrete surface. Deeper striations are more evident in high points of the concrete surface. Microcracking can reduce bond strength between substrate and overlay materials. Scarication followed by other methods such as shot blasting can reduce or eliminate these detrimental effects. Scariers, depending upon size and cutter type, can effectively remove and prole concrete from light surface proling to depths of 1/2 inch (13 mm). Removal depths greater than 1/8 inch (3 mm) are generally accomplished in multiple passes. Portable, hand-held scariers and smaller walk-behind units are often used to trim around areas otherwise inaccessible to shot blast equipment, such as around pipes and vertical edges. Scariers of any size generate dust; however, most units of any size are available with vacuum attachments that should be used. Cutter teeth are available in different compositions, sizes and congurations that directly impact efciency and performance. Equipment manufacturers should be consulted for appropriate use. B.8.5 Other surface proling methods: Other preparation methods that may be appropriate for preparation and proling of concrete substrates, such as needle scaling, scabbling, high and ultrahigh pressure waterjetting, and ame blasting, may be appropriate for use in certain oor preparation applications. This document recognizes their uses, but will not address them individually. Refer specically to ICRI Guideline 03732: Needle scalingimpacting the surface with pointed tips of a bundle of steel rods contained by a steel tube and pulsed by compressed air. Scabblingimpacting the substrate at right angle with piston-driven cutting heads to create a chipping and powdering action, driven by compressed air. High and ultrahigh pressure waterjettingwater sprayed at pressures above 10,000 psi (70 MPa) SSPC-SP 12/NACE No. 5 describes this type of cleaning. Flame blastingcombining oxygen and acetylene to produce a ame that is passed at a given height and rate over the substrate. B.9 Surface Preparation for Specic Coatings and Surfacings Categories Section B.8 provided general guidance for surface preparation and rehabilitation for all oor coating and surfacing systems. This section provides preparation guidelines for individual categories. In relative scale, thinner coatings and surfacings generally require more attention to and rehabilitation of surface

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than those in self-leveling systems, and are generally applied in thicknesses from 60 mils to 1/8 inch (1,500 m to 3 mm). Recommendations in Section B.3 regarding terminations, sawcuts and keying should be followed, as should recommendations in B 9.1 regarding substrate elevation requirements and repair of surface imperfections. Depending upon the thickness of the thick lm oor coating system, the proling techniques described in Section B.8 should result in the following concrete surface proles in accordance with ICRI Guideline 03732: Finished coating thicknesses of 2050 mils (500 1,250 m): ICRI Replicas CSP 35. Finished coating thicknesses of 50 mils 1/8 inch (125 m3 mm): ICRI Replicas CSP 46. Finished coating thicknesses of 1/8 inch1/4 inch (36 mm): ICRI Replicas CSP 59. Surface proles greater than those described may require material to be applied in increased thickness to hide prole transmitted through nished surfacings. B.9.4 Broadcast Systems: Broadcast systems generally range in thickness from 20 mils to 1/4 inch (500 m to 6 mm). Recommendations in Section B.3 regarding terminations, sawcuts and keying should be followed, as should recommendations in Section B.9.1 regarding substrate elevation requirements and repair of surface imperfections. Depending upon the thickness of the thick lm oor coating system, proling techniques described in Section B.8 should result in the following concrete surface proles in accordance with ICRI Guideline 03732: Finished coating thicknesses of 2050 mils (5001,250 m): ICRI Replicas CSP 35. Finished coating thicknesses of 50 mils1/8 inch (125 m3 mm): ICRI Replicas CSP 46. Finished coating thicknesses of 1/8 inch1/4 inch (36 mm): ICRI Replicas CSP 59. Surface proles greater than those described may require material to be applied in increased thickness to hide prole transmitted through nished surfacings. B.9.5 Mortar Flooring Systems: Mortar ooring systems are generally applied in thicknesses of 3/16 to 1/2 inch (5 to 13 mm). Minor substrate irregularities described in Section B.3 are generally overcome by application of mortar ooring systems, due to the thickness of the mortar and its subsequent compaction. Recommendations in Section B.3 regarding terminations, sawcuts and keying should be followed, as should recommendations in Section B.9.1 regarding substrate elevation requirements. Humps and high points could cause mortar to be applied in insufcient thickness to maintain the planarity of the surface. Depending upon the thickness of the mortar ooring system, the proling techniques described in Section B.8 should result in a nished coating thickness of 3/16 to 1/2 inch (5 to 13 mm) [see ICRI Replicsa CSP 59].

imperfections and general planarity than do thicker surfacings. Finished installations of thinner overlays will readily reveal surface imperfections and other substrate irregularities. B.9.1 Thick Film Floor Coating Systems: Thick lm oor coating systems generally range in thickness from 2060 mils (5001,500 m). In sections of substrate where the thick lm oor coating system is intended to terminate along edges of adjacent horizontal surfaces, termination edges should be sawcut as described in Section B.3. Examples of horizontal termination edges are doorways, openings and at in-oor perimeter work limits shown on drawings or described in specications. Areas where coatings will terminate against drains, trench drains and other objects should be sawcut. The minimum specied coating thickness should be maintained at the limits of the work, so that coating will be ush with adjacent and adjoining nished surfaces. The repair area should maintain the surface planarity of the surrounding existing substrate, without depressions or humps. The edges of repairs should be at the same elevation as adjacent existing substrate. Holes, gouges and other similar imperfections should be lled prior to coating. Depending upon the thickness of the thick lm oor coating system, proling techniques described in Section B.8 should result in the following concrete surface proles in accordance with ICRI Guideline 03732: Finished coating thicknesses of 2050 mils (501,250 m) should match ICRI Replicas CSP 35. Finished coating thicknesses of 5060 mils (1,250 1,500 m) should match ICRI Replicas CSP 46. Surface proles greater than those described may require material to be applied in increased thickness to hide prole transmitted through nished coatings. B.9.2 Self-leveling Flooring Systems: Self-leveling ooring systems generally range in thickness from 30 mils (75 m) to 1/8 inch (3 mm), but can be applied in greater thicknesses. Recommendations in Section B.3 regarding terminations, sawcuts and keying should be followed, as should recommendations in B 9.1 regarding substrate elevation requirements and repair of surface imperfections. Depending upon the thickness of the thick lm oor coating system, proling techniques described in Section B.8 should result in the following concrete surface proles in accordance with ICRI Guideline 03732. Finished coating thicknesses of 2050 mils (500 1,250 m): ICRI Replicas CSP 35. Finished coating thicknesses of 50 mils1/8 inch (1,25 m3 mm): ICRI Replica CSP 46. Finished coating thicknesses of 1/8 inch1/4 inch (36 mm): ICRI Replicas CSP 5 9. Surface proles greater than those described may require material to be applied in increased thickness to hide prole transmitted through nished surfacings. B.9.3 Slurry Flooring Systems: Slurry ooring systems are generally resin-rich systems lled with aggregates larger

B.9.6 Spray-applied Flooring Systems: Spray-applied ooring systems are generally applied at a thickness from 20

PROCEDURES FOR APPLYING THICK FILM COATINGS AND SURFACINGS OVER CONCRETE FLOORS
mils to 1/4 inch (500 m to 6 mm) or greater, depending on the resin type. Recommendations on repair of surface imperfections, terminations, sawcuts and keying in Section B.3 should be followed, as well as recommendations in B.9.1 regarding substrate elevation requirements. Depending upon the thickness of the oor coating system, proling techniques described in Section B.8 should result in the following concrete surface proles in accordance with ICRI Guideline 03732: Finished coating thicknesses of 2050 mils (5001,250 m): ICRI Replicas CSP 35. Finished coating thicknesses of 50 mils1/4 inch (1,250 m6 mm): ICRI Replicas CSP 46. Surface proles greater than those described may require material to be applied in increased thickness to hide prole transmitted through nished coatings or surfacings. B.9.7 Membranes and Membrane Flooring Systems: Membranes and membrane ooring systems are generally applied at thicknesses from 20 mils (500 m) to 1/4 inch (6 mm) or sometimes greater. Recommendations on repair of surface imperfections, terminations, sawcuts and keying in Section B.3 should be followed, as well as recommendations in Section B.9.1 regarding substrate elevation requirements. Depending upon the thickness of the oor coating system, proling techniques described in Section B.8 should result in the following concrete surface proles in accordance with ICRI Guideline 03732: Finished coating thicknesses of 2050 mils (500 1,250 m): ICRI Replicas CSP 35. Finished coating thicknesses of 50 mils 1/8 inch (125 m3 mm): ICRI Replicas CSP 46. Finished coating thicknesses of 1/8 inch1/4 inch (36 mm): ICRI Replicas CSP 59. Surface proles greater than those described may require material to be applied in increased thickness to hide prole transmitted through nished coatings or surfacings. B.10 Startup Procedures B.10.1 Facility and Environmental Conditions: Prior to daily start-up, facility and environmental conditions should comply with specication and coating or surfacing manufacturers requirements. Leaks, including those from pipes and equipment that could interfere with coating or surfacing operations, should be stopped, plugged or diverted away from the work. Doors and other ingress/egress openings that could change or alter environmental conditions if opened or left open should be barricaded or show proper signage indicating the doors are to remain closed. Substrate and air temperatures should comply with specications and manufacturers requirements during application and cure of applied materials. Relative humidity and dew point requirements should comply with specications and manufacturers instructions during application. Most coatings require the substrate surface temperature to be at least 5F (3C) above the dew point temperature. Whenever possible, installations should be done after a building has reached its

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operating temperature with the HVAC in operation for at least one week. The results of all environmental testing and results taken during the course of each workday should be recorded. Material temperatures should fall within the range of specications and manufacturers requirements. Typical material temperatures should be recorded. B.10.2 Layout of the Work Area: The project area should be arranged to facilitate material movement and smooth application procedures. Each days work should be planned so that the work progresses efciently from the furthest point to a point nearest to a central exit area. The mixing area should be located close to each days work location to facilitate staging and mixing. The oor of the mixing area should be protected with impermeable and absorbent covering to prevent damage from and facilitate clean up of any spilled materials. Polyethylene overlaid with cardboard, with the edges taped, is a typically used protection method. A sufcient quantity of materials should be staged in the mixing area to complete each days work. Materials should be arranged by product and product type. Batch numbers of products used in each days work should be recorded. Mixers, mixing equipment and safety equipment required for mixing and application should be included in the staging. A cleaning station for cleaning of equipment and tools should be set up as well as disposal collection containers. Arrangements should be made for proper disposal of debris and spent containers. B.10.3 Trafc Control: Surfaces in the vicinity of the project that are not intended to be surfaced or coated should be protected from misplacement of materials and products, as well as from the dirt, dust and debris generated from application operations. Signs and barricades should be employed to keep foot and vehicle trafc away from the oor during application and curing according to contract specications or prior agreement with the governing authority. High-visibility warning ribbon, cones and other warning materials should be prominently displayed. B.10.4 General Illumination and Lighting Requirements During Application of Floor Coatings or Surfacings: In general, SSPC-Guide 12, "Guide for Illumination of Industrial Painting Projects" provides overall and specic illumination recommendations appropriate for inclusion in specication development and use during preparation, application and inspection. Deviation from SSPC-Guide 12, however, is recommended during application of troweled mortar systems and is addressed in Section B.12.6. Work location classication should be determined to be Hazardous, Non-Hazardous or Wet, as described in SSPCGuide12, Section 5.2. Any additional lighting requirements should use xtures complying with recommendations of this section. A light meter that provides readings in footcandles should be used to determine the amount of existing light. For general work area measurements, the meter should be placed on a horizontal plane parallel with the oor or surface, as described in

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Most often, screed boxes are used to dispense resinous mortar over a oor surface to a consistent initial thickness. After a section of the oor is overlaid with resinous mortar, it is compacted with hand trowels, power trowels, or other specialized compaction equipment. Rollers: Rollers may be used for application of nal nish coats. The length of the nap controls the amount of coating delivered to the substrate and the texture of the cured coating. Non-shedding, mohair roller naps are most often used to apply nish coats of 5 mils (125 m) or less in thickness when used as a stand-alone application technique. Thicker nish coats may be applied by the use of squeegee/backroll technique, by which the material is applied by squeegee, allowed to settle, then rolled out with a non-shedding roller nap. Roller naps should be de-linted by rolling out the nap across an adhesive material such as duct tape. Several roll-out processes may be required until lint and other particles are no longer shed on the adhesive. Disc rollers are longer rollers which t into a metal frame with a central handle and are used to atten fabric or mat containing surfacings. Spiked, or porcupine, rollers pierce air/vapor pockets and are used to deaerate the applied coating or surfacing material. Looped rollers may also be used to assist in the leveling of self-leveling or slurry applications. These rollers redistribute applied materials and must be used before the materials begin to set. B.11 Pre-Application Procedures B. 11.1 Masking and Protection: Drains, trench drains, pipe openings or any other opening where errant or spent materials could enter, should be blocked off and masked. Draping and masking materials should be secure and tightly fastened around equipment and other objects and areas that require protection. Flooring terminations adjoining other surfaces should be taped off in such a way that the nished termination is neat and straight after the masking is removed. Masking or protection materials that could bond to the surface during cure should be removed immediately after any coating or surfacing application, before the coating or surfacing sets. If necessary these materials should be reapplied after cure and before succeeding coating or surfacing operations. If protection of nished ooring is required, the coating or surfacing system should cure as described in requirements, prior to placing protection materials. B.11.2 Mixing: Materials should be mixed in accordance with specications and manufacturers requirements. MSDS, specications and manufacturers data sheets with safety requirements regarding product use, including ventilation, dust control and protective personal equipment should be consulted in advance. Resins may be pre-blended using a low speed drill (maximum 450 rpm), usually 1/2 - 3/4 hp, and mixing paddle, generally a 3-bladed paddle designed to pull the mixture through the mixing head. A heavy-duty drill and paddle may be suitable for small mixes. Larger mixes may require xed-arm mechanical mixers

SSPC-Guide 12, Section 6. A minimum of 5 measurements that are representative of the work area should be made, keeping the sensor perpendicular to the surface. The measurements should be recorded and the average calculated. The measurement average should be compared to the criteria in SSPC-Guide 12 Table 1, which shows minimum and recommended work area illumination requirements in footcandles, and to SSPC-Guide 12 Table 2, which shows maximum luminance ratios. Additional lighting should be provided as described in SSPC-Guide 12, Section 7: 10 20 footcandles for general work area; 2050 footcandles for surface preparation and application; 50200 footcandles for inspection. Lighting equipment and xtures should be used and maintained as described in SSPC-Guide 12, Section 8. B.10.5 Specialty Application Equipment (from Fundamentals of Coating Concrete) Notched Squeegees: Notched squeegees are used in the application of thick lm and self-leveling or other resinrich mortar oor coating systems. Notched squeegees are generally 2 to 3 ft (0.6 to 1 m) wide, and are connected to 6 ft (2 m) handles in the rubber blade. The depth of the notches controls the thickness of the applied surfacing. Squeegees are available with notches of various depths and offer a method of applying coatings in consistent thicknesses, from 10 to 30 mils (250 to 750 m). Depending upon the viscosity of mixed resin, commercially available V-notched squeegees with notches from 1/8 to 3/8 inch (3 to 9.5 mm), yield approximately 10 mils (250 m) of coating per each 1/8 inch (3 mm) of V depth for resin viscosities approximating that of motor oil. Some examples are shown in Table B.10. Squeegees and notched trowels are available in other notch sizes and congurations that can deliver materials in varying thicknesses. They should be eld tested to determine consistent delivery range, as resin viscosity, temperature, llers and application methods will affect nal coverages. In addition, smoothness or substrate planarity will also affect delivered thickness. Rakes: Rakes are used to initially level the mortar, which is usually an aggregate-lled material, to achieve a nal compaction of 2/3 inch or greater. Gauge rakes have a cam that can be set at varying elevations to control the thickness of the applied coating. Trowels: The pressure of a straight-edged metal trowel forces dense aggregate or glass-ake-lled coating products into the pores and voids of concrete to produce a solid, smooth nish. Power trowels are often used because they provide greater compaction and leave fewer trowel marks and ridges. Screeds and Screed Boxes: Screeds are used to apply material to provide a level nished surface to a specic elevation. Metal screed bars or edging strips are set to the precise height of the nished surface, and the coating is deposited between them. A vibrating horizontal screed can be set on rails to compact the coating material and strike the surface ush with the top of the screed bars.

PROCEDURES FOR APPLYING THICK FILM COATINGS AND SURFACINGS OVER CONCRETE FLOORS
specically made for blending resinous mortars. These mixers, which are sometimes referred to as chain mixers or bucket mixers, utilize standard 5-gallon pails and are also available in 10 gallon and 15 gallon sizes, supplied with appropriate mixing vessels. Wheelbarrow-type and pedestal-type xed-arm epoxy mixers are also available, holding about 5 gallons of mixed materials. Common electric plaster/mortar mixers or paddle mixers in various sizes ranging to approximately 15 cubic feet are also available and are suitable for mixing resinous mortars. Other mixing equipment is available, generally for specic applications, with built-in metering apparatus. Hand stirring or stir sticks should not be used. Each component should be mixed separately until the ingredients are homogeneous and uniform in color. Where multiple-component materials are to be mixed, separate mixing paddles should be used for each individual component, so no component is contaminated with another until nal mixing. The product manufacturers instructions regarding mix ratios should be followed. Some manufacturers sell multicomponent products in kit form, requiring the full use of the components in each container. Other manufacturers require the components to be measured and mixed as described in specic ratios, for example 2 parts of resin to 1 part hardener. Measuring vessels should produce consistent volumes from mix to mix. When emptying components from one vessel into another, all material should be scraped from the sides and bottoms of the containers to ensure that the mix ratios are not compromised. Unless otherwise specied, products with aggregates, powders or other llers which are to be eld-added should not be added to liquids until all liquids are thoroughly mixed and blended together for three minutes, or for the duration specied by the manufacturer. Thinning is not usually recommended by manufacturers. If thinning is allowed by specication or manufacturers instructions, only solvents or thinners specically recommended by the manufacturer should be used. Solvent additions should not exceed the amount recommended by the manufacturer. The type and amount used per mix of each thinner or solvent should be recorded. Thinners and solvents should be blended into the liquids prior to addition of aggregates or other llers. The addition of thinners will affect the calculation of expected dry lm thickness from wet lm thickness measurements and may alter the performance characteristics of a particular coating. Unless otherwise specied, products with aggregates, powders or other llers which are to be eld-added to liquids should not be added until all the liquids are thoroughly mixed and blended together for 3 minutes, or for the duration specied by the manufacturer. Aggregate, powder or other llers should be added into the blended liquids using mechanical equipment that will produce a mixture with smooth, uniform consistency, free of lumps and entrapped air. The pot life and working time of specic resinous materials should be taken into account when considering use of mixing equipment. Materials with short pot lives and working times

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should be batched in smaller mixes and mixers lest they start to cure before application. Some resin-rich systems containing heavy aggregates, such as steel, garnet, granite, aluminum oxide and other llers, tend to settle quickly. If the batch contents are not dispersed directly over the oor for immediate screeding, it may be necessary to remix the material prior to use. Blended materials from previous batches should not be allowed to harden prior to mixing the next batch. Mixing equipment should be kept clean and free of hardened or cured materials and other contaminants. Solvents and thinners used for cleaning should not be used for any other purpose, and should be properly disposed of in accordance with applicable regulations. B.11.3 Priming: Most manufacturers oor coating and surfacing systems require use of primers to enhance adhesion of the system to the prepared substrate and to minimize outgassing, the release of air from concrete as concrete temperature rises. Outgassing can create pinholes and blisters in oor coatings and surfacings. System primers are typically formulated and designed to be applied at a range of 56 wet mils (125150 m) per gallon to wet out and seal the concrete substrate prior to application of the rest of the system. Most primers are low-viscosity for proper penetration into the concrete surface. Dry-lm thickness (DFT) measurements for cured primer thickness should not be used, unless otherwise specied or instructed by the surfacings manufacturer. Wet lm thickness (WFT) measurements taken immediately after applications give more appropriate indications of coverage, especially if the primer is of very low-viscosity and penetrates a permeable concrete substrate. The primer should be mixed as described in the manufacturers requirements and Section B.11.2. It may be applied by squeegee, roller, spray or brush in a uniform thickness, in a coverage range complying with specications and manufacturers instructions. Brushes or other application tools should be used to cut-in edges and around pipes, equipment, corners and other appurtenances to ensure complete substrate coverage. These areas should be cut-in to a distance sufcient to allow proper tie-in with subsequent application tools or equipment. Cut-ins should be done only as far ahead of the balance of the priming operation as is necessary to allow uniform curing of the entire priming application. The primer should not be allowed to puddle, or accumulate in low spots. If puddling occurs, the excess material should be brushed out or otherwise redistributed. Spiked shoes are recommended for walking over the wet oor after the area is primed to minimize contamination and prevent damage to the wet primer. The recommended recoat time and sequence for application of the next coating or surfacing layer should be carefully followed. Some systems require immediate application of subsequent material into wet primer, others vary by time and temperature, and others require the primer to be cured. Job

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aesthetically displeasing nishes. Uniform slip-resistance is best achieved by adding the media to the mixed resins before rolling out the material. Maintaining a specic amount of added media to a specic amount of mixed resin will promote uniformity. B.11.4. Examination of Epoxy Primers and Intermediate Coatings for Amine Blush: Cured surfaces, especially those containing epoxy, should be examined for amine blush before installation of subsequent layers. Amine blush could prevent or inhibit adhesion and contribute to intercoat delamination. All epoxies will blush given appropriate environmental conditions some more or less than others. Various formulation techniques and use of additives may reduce the degree of blushing, but not necessarily the potential for its development. A high potential for blush formation exists in areas with humid or moist conditions, or low or declining temperatures, either singly or in combination. In colder climates, isolated areas away from heat, especially near exterior walls may indicate the presence of amine blush, while other areas may not. Close inspection of the entire area is recommended, paying particular attention to susceptible isolated areas. Air-conditioned areas may also provide environments suitable for the formation of amine blush. Advanced stages of amine blush formation are easier to detect than less advanced formations. At this writing, no recognized standard or test method exists for detection of amine blush, limiting inspection to subjective powers of visual observation and touch. In its most advanced stage of formation, amine blush is evidenced by a milky-white opalescence on a surface, which will often feel very oily, greasy, or slippery. Its initial appearance might give the impression that the coating or surfacing did not cure. Less advanced formation stages may not exhibit a milky-white opalescence, and may present only a slight oily or greasy residue, difcult to feel. This stage of formation is the one that can easily be overlooked or not recognized. Amine blush can be removed by detergent washing. Solvent washing is sometimes used, but it is a less desirable removal technique as copious amounts of solvent are required to effectively remove the material. Residues may leave chloride

specications and the manufacturers data sheet and application instructions should be consulted for specic directions. If succeeding applications require material to be applied into wet primer, priming should be limited to the area that can be covered with succeeding material while the primer is still wet. If the primer cures or sets prior to application of a succeeding coat, the specications or manufacturers instructions for corrective action should be consulted. Usually those areas are required to be re-primed, but specic corrective action can vary by system. If the succeeding application requires the primer to be cured, some manufacturers recommend that the primer be seeded with dry, clean aggregate, generally 35 mesh to 60 mesh, depending upon thickness of the ooring system. After the primer has been applied and allowed to settle out, clean, dry aggregate of the required size should be broadcast in a raining action, either by hand or by use of a specially designed blower . Aggregate should not be thrown directly at or into the wet primer or the primer may separate and crater. Aggregate should be broadcast in such a way that the primed area is full, but not saturated. No dry spots where excess aggregate has accumulated should be visible. The area should still appear to be wet after the aggregate is distributed. When using dry silica for seeding primer, for example, proper, even distribution consumption is approximately 15 to 20 ft2 (1.39 to 1.85 m2) per pound of aggregate. Heavier aggregates such as garnet, granite and aluminum oxide will provide less coverage per pound. Aggregate type and size are generally determined by anticipated trafc, chemical exposure and cleanability requirements. The use of a specic medium and size should conform to specications and manufacturer's requirements. Aluminum oxide and garnet are harder than silica and are generally more tolerant of most chemical exposures. Silica is the most readily available and least expensive medium used for slip resistance. Steel aggregate is most often used where its malleable qualities afford good resistance to impact. Polypropylene beads are most often used where cleanability and sanitation are high priorities. Combinations of these media can also be used. Broadcasting the media into the applied material generally results in uneven dispersion, creating slippery areas and

Table B.10 Effect of Notch Depth and Resin Viscosity on Surfacing Depth Depth of Applied Surfacing Resin Viscosity Approximating: Motor Oil Syrup 10 mils (250 m) 5 mils (175 m) 15 mils (375 m) 10 mils (250 m) 20 mils (500 m) 15 mils (375 m) 30 mils (750 m) 25 mils (625 m)

Depth of Squeegee Notch 1/8 inch (3 mm) 3/16 inch (5 mm) 1/4 inch (6 mm) 3/8 inch (9.5 mm)

Water 30 mils (750 m) 45 mils (1,125m) 60 mils (1,500 m) 75 mils (1,875 m)

PROCEDURES FOR APPLYING THICK FILM COATINGS AND SURFACINGS OVER CONCRETE FLOORS
salts and other bond-inhibiting contaminants on the surface. Effective solvent washing requires several applications to ensure the contaminants are not simply re-dispersed. Blush is best removed by use of a oor scrubber with detergent and warm water, followed by a thorough rinse of the scrubbed surface. The surface should be allowed to dry completely before re-inspection. If blush is detected, the surface should be rewashed, rinsed and again allowed to dry before inspection. Usually amine blushing is easily removed with a single wash and rinse. During winter months in colder climates, or at any time or location where conditions may be likely to produce amine blush, it may be appropriate to treat the surface as if amine blushing is present but undetected. B.11.5 Inspection for Other Contaminants: Depending on the facility or operation, ongoing processes may generate dirt, dust, or oily mists can collect on surfaces after cure. After the applicators leave the area, people may walk over cured or uncured surfaces, tracking contaminants onto the surface. The cured surface should be inspected for other contaminants that may have formed during or following cure. Removal of any contaminants prior to subsequent surfacing application is necessary for proper adhesion. B. 12 Application of Surfacing B.12.1 Coved Base: Integral coved base turned-up vertical abutments, such as walls and equipment pads offer unique sanitation and cleanability features in resinous oor coating and surfacing systems. In the ooring systems described below (with the exception of troweled mortar ooring systems), coved base is formed separately from the surfacing system. In most ooring systems, formed bases are generally coated or surfaced with the same neat resins as the ooring matrix, but without aggregates. The coved base should be installed according to contract specications and manufacturers recommendations. Its substrate should be sound, stable and prepared as described in Section B.7. If the specied ooring system is other than troweled mortar ooring, the coved base, spoon cove or splay is formed with resinous or polymer-cementitious mortar. The coved base should be overcoated using the same resins as the oor coating or surfacing material, as described in the contract specication and the surfacing manufacturers instructions. The nished base should be neat, straight and without surface irregularities. B.12.2 Thick Film Floor Coating Systems: Thick lm oor coating systems applied by methods other than spray application (which is discussed in Section B.12.8), are generally 100% solids systems, such as epoxies; or low VOC systems, such as urethanes, incorporating chemically cured resins with inert llers applied in single or multiple layers. They produce a cured thickness greater than 20 mils (500 m), but usually not more than 60 mils (1,500 m). Thick lm ooring systems, applications and procedures vary by manufacturer and sys-

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tem. Specic application requirements should be carried out as described in the contract specication and the surfacing manufacturers instructions. Substrate surface irregularities should be patched, repaired and otherwise rehabilitated prior to application, as described in Section B.3. The entire substrate surface should be in plane, and all dings, holes, spalls and other surface imperfections should be lled with smooth repair transitions. If required, the substrate should be primed as described in Section B.11.3 the contract specication and the surfacing manufacturers instructions. Instructions on recoat times should be strictly followed. If an epoxy primer is used and allowed to cure, the primer should be inspected for amine blush as described in Section B.11.4 prior to application of any succeeding coatings or surfacings. Succeeding coatings should be applied uniformly, ensuring that the coating is applied within required wet lm thickness (WFT) ranges to reach specied dry lm thicknesses (DFT). Wet edges should be maintained by working new batches into wet edges of previously applied material to eliminate cold joints. The exact delivery thickness of specic resins should be determined by eld testing. The squeegee blade should be kept perpendicular to the oor surface or the delivery thickness will be reduced or inconsistent. Squeegee blades should be kept clean and free of resin build-up. As squeegees wear down from use, materials will be applied in thinner yields. If wet lm measurements show insufcient thickness, squeegees should be inspected for wear. Worn blades should be replaced. Depending upon its working time, the applied material should be allowed to settle out, then deaerated. Ensure deaeration techniques are completed before the applied material begins to take initial set. Applied coatings may be deaerated by use of porcupine or needled rollers manufactured for this purpose. Porcupine rollers should be used in a perpendicular direction to that in which the coating was initially applied. Epoxy primers should be inspected for the presence of amine blush as described in Section B.11.4 before application of subsequent or nish coats. To ensure full coverage and leveling, nish coats should be rolled in two operations, with the second rolling at right angles to the rst. Any masking materials should be removed according to Section B.11.1. Providing Slip Resistance: Adding specically sized or graded aggregates such as aluminum oxide, garnet, steel, silica or polypropylene beads to the nal nish can promote slipresistance. Thicker ooring systems may utilize other methods that will be described in the following sections. The aggregate type and size are generally determined by anticipated trafc, chemical exposure and cleanability requirements. The use and size of any specic aggregate should be determined in accordance with the specication and manufacturer's requirements. Aluminum oxide and garnet are harder than silica and are generally tolerant of most chemical exposures. Silica is the most readily available and least expensive medium used for slip resistance. Steel aggregate is most often used where its malleable qualities afford good resistance to impact. Polypropylene beads are most often used where cleanability and sanitation are

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application as do self-leveling ooring systems. Slurry systems are generally applied in thicknesses from 60 mils (1,500 m) to 1/8 inch (3 mm). If an epoxy primer is used and allowed to cure, the primer should be inspected for amine blush as described in Section B.11.4 prior to application of any succeeding coatings or surfacings. Slurry material should be applied as described in the contract specication and the surfacing manufacturers instructions. The mixed material should be poured in ribbons in application areas and should be applied to the specied thickness, maintaining wet-edges as described in Section B.12.2. Slurry material is generally applied to the thickness of the largest aggregate by scrape-troweling, but it may be applied to a specic thickness by gauge rake, pin screed, or notched trowel. Wet-lm thickness measurements should be taken with sufcient regularity to conrm that the specied thickness is uniform. The applied material should be allowed to settle out, then deaerated. Subsequent nish coats should be applied as described in Section B.12.2. Joints should be treated as described in Section B.13.1. B.12.5 Broadcast Flooring Systems. Broadcast ooring systems can be installed by applying unlled or lled resinous receiving coats by roller, spray, squeegee or trowel, then broadcasting selected aggregates into the receiving matrix while the matrix is still wet and uncured. Broadcast systems generally range in thickness from 20 mils (500 m) to 1/4 inch (6 mm). If an epoxy primer is used and allowed to cure, the primer should be inspected for amine blush as described in Section B.11.4 prior to application of any succeeding coatings or surfacings. The receiving coat may be neat resins or resinous slurry materials. It should be applied as described in the contract specication, the surfacing manufacturers instructions and the recommendations in Section B.12.2. After the receiving coat has settled out but is still wet, the selected aggregate should be broadcast into wet matrix, preferably by means of commercially available aggregate blowers. The aggregate should be broadcast in a raining fashion so that it falls as perpendicularly as possible into the wet matrix. If the aggregate is thrown directly at the wet matrix, it may cause blowouts or separation of the resin from the aggregate particles. The application of the receiving matrix and the broadcasting of the aggregate must be performed in nearly simultaneous operations to ensure the broadcast aggregate is properly received and has time to settle and wet out. The aggregate should be broadcast to saturation within a few inches of the edge of the applied receiving coating to allow for proper tie-in of subsequent receiving coats. Uniform dispersal of the aggregate should continue until no wet spots show. As the aggregate continues to settle and wet out, wet areas may appear. Additional aggregate should be broadcast into these areas until they appear dry. After cure of the broadcast matrix, loose aggregate should be removed by sweeping and vacuuming. If the system or specication requires additional layers of broadcast lled matrix, the operation should be repeated. If the system or specication requires grout coats or nish coats, ensure that materials applied subsequent

high priorities. Combinations of these media can also be used. Broadcasting media into the applied material generally results in uneven dispersion, creating slippery areas and aesthetically displeasing nishes. Uniform slip-resistance is best achieved by adding the media to the mixed resins, then rolling out the material. Maintaining a ratio of a specic amount of added media to a specic amount of mixed resin will contribute to the desired uniformity. Both specier and applicator may supply samples of various nished textures, but selection of the nal texture should be made by the user. B.12.3 Self-leveling Flooring Systems: Self-leveling ooring systems are generally 100% solids or low VOC systems incorporating chemically-cured resins with inert llers and powders, applied in single layers that have a cured thickness greater than 30 mils (750 m), but usually not more than 1/8 inch (3 mm). Self-leveling ooring system applications and procedures vary with the surfacing manufacturer. Specic application requirements should be carried out according to contract specication and the surfacing manufacturers instructions. Substrate surface irregularities should be patched, repaired and otherwise rehabilitated prior to application, as described in Section B.3. The entire substrate surface should be in plane, with all dings, holes, spalls and other surface imperfections lled with smooth repair transitions. Surface imperfections tend to reect through nished thin lm coatings, requiring greater attention to nished substrate surface detail than do thicker surfacing applications. If metal or plastic strips are to be utilized, they should be installed according to contract specications and manufacturers instructions. If required, the substrate should be primed as described in Section B.11.3, the contract specication and the surfacing manufacturers instructions. If an epoxy primer is used and allowed to cure, the primer should be inspected for amine blush as described in Section B.11.4. Instructions on recoat times should be strictly followed. The self-leveling material should be applied according to contract specication and the manufacturers instructions. Succeeding coatings should be applied uniformly, ensuring that the coating is applied within the wet lm thickness range required to achieve the specied dry lm thickness. Wet edges should be maintained by working new batches into wet edges of previously applied material to eliminate cold joints. Pin-screeds or gauge rakes may also be used for application, especially for applied thicknesses of 1/8 inch (3 mm) and greater. Joints should be treated as described in Section B.13.1 B.12.4 Slurry Flooring Systems: Slurry ooring systems are generally 100% solids or low VOC chemically cured resins, incorporating use of inert llers and powders. Specic application requirements should be carried out as described in the contract specication and the surfacing manufacturers instructions. Slurry ooring systems are generally resin-rich systems lled with aggregates larger than self-leveling systems, troweled or squeegeed to the thickness of the largest aggregates. While resin-rich, these systems do not tend to ow out as readily after

PROCEDURES FOR APPLYING THICK FILM COATINGS AND SURFACINGS OVER CONCRETE FLOORS
to the rst grout coat are inspected for amine blush. Generally, broadcast matrices without grout coats and/or topcoats are very rough and difcult to clean. The nished texture is determined by the size of the aggregate used or the thickness of subsequently applied coatings. Joints should be treated as described in Section B.13.1. B.12.6 Troweled Mortar Flooring Systems: Mortar ooring systems are generally less resin-rich than other ooring systems, and are lled with larger proportions of blended aggregates. Mortar systems are generally applied by using trowels, gauge rakes or various types of screed-boxes to disperse the material to a selected thickness. The mortar system is then compacted to its specied thickness with trowels, power trowels, or other compaction equipment. Mortar ooring systems are generally applied in thicknesses of 3/16 inch (5 mm) to 1/2 inch (13 mm). Troweled mortar systems are best applied in low general lighting conditions with the task lighting directed across the oor surface from a low angle, casting shadows where applied mortar is out of plane. Low general lighting conditions allow reduced task lighting requirements and greater worker comfort levels when task-light luminance ratio is a maximum of 5:1, as indicated in SSPC-Guide 12, Table 2. Trowel ridges and other irregularities in the applied mortar can be more readily and immediately detected and corrected by the ooring mechanic during application by use of contrasting lighting. Substrate surface irregularities should be patched, repaired and otherwise rehabilitated prior to application, as described in Section B.3, ensuring that the entire substrate surface is in plane and otherwise prepared to allow smooth transitions. Metal or plastic strips should be installed according to contract specications and manufacturers instructions. If required, the substrate should be primed as described in Section B.11.3, the contract specication and the surfacing manufacturers instructions. Recommended recoat times should be followed. If an epoxy primer is used and allowed to cure, the primer should be inspected for amine blush as described in Section B.11.4 prior to application of any succeeding coatings or surfacings. Mixed mortar should be spread with trowels, gauge rakes, screed boxes or other devices to an initial thickness sufcient to achieve specied cured thickness after subsequent compacting. Wet edges should be maintained. New mortar should be compacted to within a few inches of the edge of previously applied mortar to allow proper tie-in of subsequent compaction. Prior to mortar set, compacted areas should be inspected for irregularities or imperfections that can be corrected or removed, and necessary repairs should be made prior to cure. If work is stopped for breaks, lunches or at days end, it should terminate at natural stop points, such as joints or termination strips, to minimize the appearance of cold joints. Terminations should be neat and straight. If integral coved base is part of the project requirements, a work crew of sufcient size should be available to install the coved base just ahead of the mortar ooring application to permit proper tie-in and elimination of cold joints. If specied or allowed by owners representative, plastic or metal

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termination strips may be set on the oor to allow application of the coved base prior to the installation of the oor. Some mortar matrices, especially those with volumetric aggregate to resin ratios of greater than 4:1, exhibit some degree of porosity when viewed under magnication, and may require grout and/or nish coats to ll matrix and surface porosity. The surface should be inspected for amine blush prior to application of grout coats or nish coats. The nished surface texture is determined by the size of the broadcast aggregate used and/or thickness of subsequently applied coatings. Joints should be treated as described in Section B.13.1. B.12.7 Fabric and Mat Reinforcement: Fabrics and mats, generally referred to as berglass, are usually supplied in rolls in varying widths. They may be incorporated as embedments in specic resinous systems to increase strength, durability, impermeability to chemical or solvent attack, resistance to high temperatures or thermal shock, and crack resistance. This reinforcement may also serve to reduce curing shrinkage of some resins. Certain fabrics and mats may be used in membrane systems and in systems designed for high chemical resistance and heavy mechanical exposure. Fabrics can be knitted, woven, nonwoven, directional or non-directional, and are manufactured in many different types, strengths, weights, weaves, elasticities and generic makeups. Mats, usually chopped strand mats, are made by bonding glass ber strands together with adhesive binders. Reinforcing fabrics and mats are available with a wide variety of different characteristics. Manufacturers design ooring systems to meet specic performance standards, integrating specic fabric and resin idiosyncrasies and properties. Unless otherwise specied, fabric or mat reinforcement should not be used in any coating or surfacing system unless its manufacturer has published system data sheets and application procedures describing the system and the specic fabric to be used. Systems may employ the use of a single layer of mat or fabric or multiple layers of different combinations. The general procedures for most berglass applications are similar, but each particular system should be applied according to contract specications and the manufacturers instructions. Areas to be surfaced are generally laid out to minimize cuts and material handling. Pre-cut glass should be sufciently oversized to allow ease of placement and handling. Glass should be loosely folded into 36 ft (12m) sections. To ensure pre-cut glass is kept clean and dry, it should be stored near the immediate work area. The specied base coat, which may be unlled or lled with aggregates, powders or other proprietary llers, should be applied to the specied thickness over specied coated or uncoated substrate. Next, the rst fold of glass should be unfolded and laid on the wet base coat, pressing the placed glass into the matrix with a trowel or roller. To minimize crimping and wrinkling, troweling or rolling should proceed from the middle of the glass toward its edges. Continue unfolding the rest of the length and working glass into place. To deaerate the composite, the applied reinforcement should be saturated with the specied clear resin, then rolled out with a serrated or

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ited uniformly. Deviation from this procedure generally results in uneven lm build. Brush out or otherwise remove sags and runs from vertical surfaces. Airless spray equipment is often used in application of thick lm coatings. The equipment manufacturers safety instructions should be consulted prior to use. The equipment should be sufciently sized to properly spray high viscosity materials as described in the surfacing manufacturers requirements, using thinners only as recommended by the surfacing manufacturer. Spray application should follow the contract specications and the surfacing manufacturers requirements. Substrate surface irregularities should be patched, repaired and otherwise rehabilitated prior to application, as described in Sections B.3. The entire substrate surface should be in plane, and all dings, holes, spalls and other surface imperfections should be lled with smooth repair transitions. Surface imperfections tend to reect through nished thin lm coatings, requiring greater attention to nished substrate surface detail than do thicker surfacing applications. If required, the substrate should be primed as described in Section B.11.3, the contract specication and the surfacing manufacturers instructions. Instructions on recoat times should be strictly followed. Masking and protection, as described in Section B.11.1, are important in spray application. Atomized overspray travels further than roller or trowel spatter that may require additional protective coverings. Prior to their application, material components should be pre-mixed and then adequately blended according to the surfacing manufacturers instructions. Most ooring materials are 100% solids and are designed to be installed without use of thinners or solvents. All materials should be applied according to contract specications and the surfacing manufacturers instructions. Coating should be spray applied in uniform layers, with the edges of the spray pattern overlapping sufciently to ensure complete coverage. Fast-cure systems, such as polyureas, are best applied using a crosshatch technique to minimize lap marks. Different nish textures can be created by positioning the gun at different distances from the surface in systems with fast gel times. Depending on the gel time of the material and the distance from the surface, textures can range from an orange peel to a heavy stipple. This texture will help to add to slip resistance and create a more uniform nished appearance. Certain spray-applied materials, especially those applied by heated plural component equipment, may cure too quickly for conventional thickness testing. Nondestructive, ultrasonic dry lm thickness gauges are commercially available and can be used to determine cured thicknesses over concrete substrates, provided that the coatings and surfacings are not aggregatelled. Destructive testing, such as by Tooke gauge or cutting cured coating and measuring with a micrometer, are other methods of measuring fast-curing lm thickness. Destructive testing should only be used when specied, and the test area should be repaired according to contract specications and the surfacing manufacturers requirements.

ribbed roller specically intended for this operation. The reinforcement should be rolled vigorously until it loses its color and becomes translucent, indicating that it is thoroughly wet-out. However, the saturant coat should not be allowed to puddle. If allowed by the manufacturer or specication, the saturated reinforcement should be lightly seeded by broadcasting clean, dry aggregate in a size and type specied or approved by manufacturer, as described in Section B.12.5. Protrusions and wrinkles should be ground off following cure. Any areas of glass that are dry and not fully saturated should be cut out, and voids and repaired areas should be lled with the specied resin or mortar before installation of remainder of the system. If additional layers of glass reinforcement are required, they should be applied as outlined in this section or as specied or required by manufacturers instructions. B.12.8 Spray-Applied Flooring Systems: Some thicklm ooring systems may be spray-applied. Some parts of other ooring systems, such as primers or nish coats may be spray applied. Certain ooring systems such as polyurea systems are generally spray-applied. Spray-applied systems can be sprayed from 20 mils (250 m) to 1/4 inch (6 mm) and greater. Plural component equipment is often used with fastcuring materials. Correct and consistent proportioning is critical for applied systems to cure correctly and to meet published performance data. Some resin systems require specic spray equipment for proper application, and the manufacturers recommendations should be followed for best results. Most plural component equipment functions best with preheated materials, in-line heaters and/or heated lines, which serve to reduce material viscosity. Some materials, such as polyureas, may require preheating to specic temperature ranges prior to spraying. Thermostatically controlled band heaters placed around the bottom, midsection and top of drums are generally used for this purpose. The material should be agitated during heating process for uniform heating and to eliminate hot spots. Be aware that heating may take several hours depending upon temperature, age of material and pigment load. In some applications transfer pumps are used to assist the high volume movement of material from material containers to the lines and nally to the gun where the material is mixed and sprayed. To allow continuous material ow, especially when bers or akes are utilized, appropriate in-line lters should be used. When pumping material from drums, drum mixers should be used as described in the surfacing manufacturers requirements. If required, the substrate should be primed as described in Section B.11.3, the contract specication and the surfacing manufacturers instructions. Recommended recoat times should be followed. If epoxy primer is used and allowed to cure, the primed surface should be examined for amine blush as described in Section B.11.4 prior to application of succeeding coat. The gun should be held perpendicular to the surface at a distance that will ensure that a wet layer of coating is depos-

PROCEDURES FOR APPLYING THICK FILM COATINGS AND SURFACINGS OVER CONCRETE FLOORS
The surfacing manufacturers re-coat and tie-in procedures should be strictly followed. Subsequent coats or layers of material should be applied in accordance with contract specications and the surfacing manufacturers instructions. Some fast-cure systems require scarication, abrasion and/or softening existing coating with special solvent prior to the next application. If the coating or surfacing is hard and not elastomeric, joints should be treated as described in Section B.13.1. If the spray-applied coating is exible or elastomeric, joints and cracks should be treated as described below. B.12.9 Safety Considerations for Spray Applications: Safety procedures are important in all aspects of ooring applications, however, safety requirements in spray applications may be more complex than those required in traditional ooring application methods. While this document does not address specic safety procedures, those requirements and procedures pertaining to spray application should be investigated and followed. Some considerations include, but are not limited to: Hazards of spraying in closed spaces Equipment grounding Safety controls to prevent hypodermic injection of coating into persons from gun tips and leaks from high-pressure ttings, connections and hoses Integrity of high-pressure air line ttings, connections and hoses All equipment must be suitable for its intended purpose, capable of properly atomizing the coating to be applied, and equipped with appropriate pressure regulators and gauges. The equipment shall be maintained in proper working condition. Spray equipment shall meet the material transfer requirements of the local air pollution or air quality management district. Spray equipment shall be kept sufciently clean so that dirt, cured coating, and other foreign materials are not deposited in the coating lm. Any solvents left in the equipment shall be removed before using. Compressed air, if used, must be tested in accordance with ASTM D 4285, and must be clean and dry. Electrical power, including proper voltage, amperage and grounding requirements must be met. B 12.10 Membranes and Membrane Flooring Systems: Membranes and membrane ooring systems are used either as an underlayment component of a harder coating or surfacing applied over it, or as a stand-alone system. Membranes and membrane ooring systems can be unreinforced or reinforced with berglass or textiles. Membranes and membrane ooring systems are generally applied at thicknesses from 20 mils (500 m) to 1/4 inch (6 mm) or sometimes greater. Substrate surface irregularities should be patched, repaired and otherwise rehabilitated prior to application, as described in Section B.11.3. The entire substrate surface should be in plane, and all dings, holes, spalls and other surface imperfections should be lled with smooth repair transitions. If required, the substrate should be primed as described in Section B.11.3, the contract specication and the surfacing manufacturers instructions. Instructions on recoat times should be strictly followed. If

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an epoxy primer is used and allowed to cure, the primer should be inspected for amine blush as described in Section B.11.4 prior to application of any succeeding coatings or surfacings. If metal or plastic strips are to be used, they should be installed according to contract specications and manufacturers instructions. If the membrane is used as a crack dampener over cracks, it may be installed with or without berglass reinforcing, according to contract specication or manufacturers instructions. The membrane should be applied to the required thickness, and centered over the crack at least 3 inches (76 mm) from either side. Some systems require cracks to be caulked with sealant prior to membrane application. In these cases, they should be sealed with the recommended sealant and allowed to cure prior to membrane application. If a reinforcement is used, it should be embedded into a wet matrix and saturated with additional membrane. In projects where the entire oor is to be surfaced with a membrane, cracks and joints should be treated according to contract specications and manufacturers instructions. Some systems may require joints and cracks to be pre-sealed. Other systems may require additional stripe coats or stretch coats to be applied over cracks and joints without pre-sealing. The base coat should be applied by squeegee, notched squeegee, pin-screed, notched trowel, roller, brush or spray to achieve specied thickness. If subsequent coats are required, the surface should be inspected for amine blush before application of any subsequent coating as described in Section B.11.4 B.13 Treatment of Joints after Application Joints are generally placed on column lines, around heavy equipment and equipment pads and around other areas where isolated movement may occur, especially if moving cracks have been observed during the preparation process. Chalk lines should be snapped to indicate placement of new joints. New joints should be sawn in neat, straight lines. Unless otherwise specied, joints should be sawcut through the nished coating. Existing joints should be sawcut to their original width and depth. Benchmarks should be removed. Chalk lines should be snapped over the centers of joints. After sawing, the joint should be vacuumed to ensure it and adjacent areas are dry, clean and free of all dirt, dust, debris and other contaminants. New joints should be sawcut according to contract specications in neat, straight lines to a width of 1/4 inch (6 mm) and depth of 1/2 inch (13 mm), unless otherwise specied. If the contract specication or the surfacing manufacturer requires joints to be covered with coatings or surfacings without other special treatments, appropriate sealant should be installed as described in the contract specication and the surfacing manufacturers instructions. Where the joint width and depth are greater than 1/4 x 1/4 inch (6 x 6 mm), the depth of sealant should be one-half the width of the joint, generally not exceeding a minimum width of 1/4 inch (6 mm) and a maximum depth of 5/8 inch (13 mm). Joint llers, such as dry sand, or commercially

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B.14.2 Touchup: Any coating or surfacing irregularities discovered after the masking and protection have been removed should be touched up as described in the repair procedures approved by the owners representative. B.14.3 Equipment: All equipment, tools and unused materials should be removed from the site. The owners representative should be provided with written environmental and physical requirements to ensure that the installed ooring system reaches nal cure without damage. Written requirements should include: Duration of time to restrict foot trafc and wheeled trafc from oor. Duration of time to restrict chemicals from engaging oor surface. Duration of time to maintain required minimum and maximum temperatures. Duration of time to maintain minimum and maximum relative humidity. Other requirements. The owners representative should be provided with a list of any required types and quantities of materials, if specied. B.14.4 Maintenance Requirements: Written maintenance requirements should be provided to the owners representative. B.14.5 Protections: If required by contract specication or agreement, the oor should be protected as specied or with an appropriate protection material, such as plywood or composite board with taped joints, laid over polyethylene sheets.

available backer materials, such as closed cell foam, can be used to control sealant depth. The sealant should adhere to both sides of the joint but not to its bottom or to any backer material, as three-point bonding generally results in sealant failure. Sealant generally will not bond to commercially available backer rods. Bond-breaking material, such as a polyethylene strip or plastic-faced electrical tape, should be placed over other backer materials to prevent adhesion. Masking tape should be placed along both sides of the joint to maintain neat, straight lines after the sealant is installed. If priming is recommended, the sealant should be installed so that the joint is full and ush with adjacent edges. Masking tape should be removed prior to joint cure. B.14 Post Application Procedures B.14.1 Cleanup: The project area should be left in a broom-clean condition, or the condition required by the contract specication. All masking and protection should be removed, especially from drains, equipment and entries. Drains that have collected dirt and debris should be vacuumed and cleaned. Cured resinous materials that may have adhered to the inside or outside of drain should be removed. Tape adhesives remaining on surfaces after masking and protection are removed should be cleaned off. All spatter and errant materials, cured and uncured, should be removed from surfaces not intended to receive coatings and surfacings. All trash and construction debris should be properly disposed off-site or in designated disposal areas.

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