Application Guide for an Epoxy System for Parking Floors

The purpose of this document is to provide guidelines to applying an epoxy system with primer and topcoat for parking floors.

1. Preparation

1.1 Assessment and Planning

• Evaluate the Floor Condition: Inspect the floor for cracks, moisture, and existing coatings.

• Safety Measures: Ensure proper ventilation. Use PPE such as gloves, masks, and safety glasses.

  1.2 Moisture Testing

Importance: Ensuring the concrete is sufficiently dry is crucial for proper adhesion, blistering, bubbling, and longevity of the epoxy.

Common Methods:

• Calcium Chloride Test (MVER test) (ASTM F1869):

  • Procedure:

    • Choose test locations that are representative of the entire area; multiple test points are necessary.
    • Clean the test area thoroughly.
    • Place the calcium chloride container on the floor and cover it with a plastic dome, sealing the edges with tape.
    • Leave it for 60 to 72 hours.
    • Measure the weight gain of the calcium chloride.

  • Acceptance Criteria: The moisture emission rate should be less than 15 gr per m² per 24 hours.

• Relative Humidity (RH) Test (ASTM 2170):

  • Procedure:

    • Choose test locations that are representative of the entire area; multiple test points are necessary.
    • Drill small holes in the concrete slab to a minimum depth of 40% of the slab thickness.
    • Insert the test probes into the holes.
    • Record readings of the RH using a digital reader.

  • Acceptance Criteria: The RH should be less than 75% at the depth of the concrete slab.

2. Surface Preparation

2.1 Cleaning the Surface

• Remove Debris: Use a broom or blower to clear loose debris.

• Degreasing: Apply a degreaser to remove oil and grease stains, then scrub the surface and rinse thoroughly.

• Power Washing: Use a power washer to remove any remaining dirt and contaminants.

• Drying: Allow the surface to dry completely.

  2.2 Repairing the Surface

• Fill Cracks and Holes: Use an epoxy patching compound to fill any cracks or holes.

• Curing: Allow it to cure according to the manufacturer’s instructions (24 hours).

• Smoothing: Smooth the surface and vacuum clean loose powder.

  2.3 Etching or Grinding

• Etching: Apply a 15% diluted muriatic acid etching solution to the concrete to open its pores, enhancing epoxy adhesion. Rinse thoroughly and let dry.

3. Priming

Prerequisite: Ensure that the air temperature and the relative humidity are within limits specified by the manufacturer during application.

3.1 Mixing the Primer

• Read Instructions: Follow the manufacturer’s instructions for the correct mixing ratio.

• Combine Components: Stir the resin using a paddle mixer until completely homogeneous. Pour the hardener into the resin container and mix until the hardener is well distributed and a streak-free mass is produced. Transfer the mixture to a clean container and mix the components again

  3.2 Applying the Primer

• Tools: Use a roller or squeegee for even application.

• Coverage: Apply a uniform layer, avoiding puddles, following the manufacturer’s instructions for the consumption rate.

• Curing: Allow the primer to cure as per the manufacturer’s instructions (12-24 hours).

• Scatter: Where required, scatter carefully selected quartz on top of the fresh primer layer as per prescribed particle size and consumption rate.

4. Applying the Epoxy Base Coat

4.1 Mixing the Epoxy Base Coat

• Accurate Measurement: Ensure accurate measurement of the resin and hardener if partial quantities are to be mixed.

• Combine Components: Stir the resin using a paddle mixer until completely homogeneous. Pour the hardener into the resin container and mix until the hardener is well distributed and a streak-free mass is produced. Transfer the mixture to a clean container and mix the components again.

• Additives: Add color pigments, if supplied separately, and anti-slip additives if required.

  4.2 Application Process

• Remove Unbound Particles: Where quartz scatter is applied, remove the unbound particles using a plastic broom.

• Pouring: Pour the mixture onto the floor in sections.

• Spread and Roll: Use a squeegee to spread the epoxy and a short-pile roller to even out the coating and remove air bubbles. Apply in a crisscross pattern as per the prescribed consumption rate.

• Work in Sections: Maintain a wet edge to avoid overlap marks.

• Curing: Allow the base coat to cure as specified by the manufacturer (12-24 hours).

• Scatter: Where required, scatter carefully graded quartz on the top of the fresh base coat layer as per prescribed particle size and consumption rate.

5. Top Coat Application

5.1 Mixing the Top Coat

• Read Instructions: Follow the manufacturer’s instructions for mixing.

• Combine Components: Mix the top coat resin and hardener thoroughly as per the specified time.

  5.2 Applying the Top Coat

• Application: Use a roller or squeegee to apply evenly over the cured base coat.

• Coverage: Ensure a uniform layer for protection and finish as per the manufacturer’s guideline.

• Curing: Allow the top coat to cure completely as per the manufacturer’s instructions (24 hours).

6. Finishing and Inspection

6.1 Curing Time

• Initial Cure: Avoid foot traffic for at least 24 hours.

• Full Cure: Wait at least 5 days before allowing vehicle traffic to ensure full curing.

  6.2 Inspection

• Check for Defects: Inspect for air bubbles, missed spots, or uneven coverage.

• Touch-Ups: Perform necessary touch-ups with mixed epoxy.

Additional Tips:

• Environmental Conditions: Maintain manufacturer’s recommended temperature and humidity levels during application and curing.
• Application Speed: Work efficiently to maintain a wet edge and avoid premature curing.
• Professional Help: Consider professional assistance for large-scale applications or if unsure about any step.

By following these detailed steps, you can ensure a high-quality and durable epoxy floor for your parking area that includes both a primer, base coat, and a protective topcoat.