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COMMERCIAL / INDUSTRIAL SERVICES
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The Process
The installation process on commercial/industrial projects varies depending on the systems selected, the environment and other special requirements. In general terms, the installation process includes the following basic steps:
1. Surface preparation
2. Crack patching and control joint filling
3. Application of primer coat
4. Installation of coating system
5. Curing time
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| Surface Preparation |
An essential factor governing the performance of any protective coating system is the condition and preparation of the concrete surface. Before applying protective coating systems, it is necessary to ensure that the concrete is clean and mechanically sound. The need for adequate surface preparation cannot be overemphasized. Insufficient attention to this step in the process may cause the coating system to fail.
Depending on the project, floor conditions will determine the type of surface preparation that is required (i.e., milling, decontamination, degreasing, shot blasting and wet or dry grinding).
Contaminates must be removed from the floor surface to allow proper adhesion of the new floor coatings. Some contaminates, such as oil and grease, can be washed away with a degreaser. Other contaminates, such as concrete curing compounds or sealers, must be removed mechanically with a shot blaster and/or grinder to ensure adequate removal. Concrete curing compounds or sealers are often applied when the concrete is poured to help with the curing process. After the concrete is poured and cured, it is difficult to determine visually whether a curing compound or sealer was used; and in many cases the owner has no idea who installed the concrete or how it was installed.
Curing compounds and sealers must be removed to allow the new floor coatings to bond properly to the concrete surface. If the compound and sealer contaminates are not removed this could result in the floor coatings peeling off only months after they are installed. Needless to say, the coatings would have to be reapplied, leading to loss of use, inconvenience and much disappointment for the customer. Some floor coating companies prefer to use acid etching to prepare the concrete surface. Acid etching is a wet, messy process, and will not remove the curing compounds and sealers. If the acid comes in contact with any metal surfaces or seeps into cracks down to the rebar embedded in the concrete, it could cause them to rust and deteriorate. Further, the acid etching materials are considered a health hazard.
That is why Ervin Specialty Coatings prepares old and new concrete floors by grinding and/or shot blasting, which is the most reliable method for preparing concrete surfaces for floor coatings. The grinding/shot blasting process removes a thin layer of concrete, along with stains, dirt, and oils, and allows for superior bonding of the coating materials, which cannot be achieved with harmful chemicals and water based cleaners. In addition to the reasons already specified, this method of surface preparation is a superior method, because it helps smooth out pitted floors, flattens and smoothes out poorly finished and uneven surfaces, and creates a more uniform finish.
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