Urethane Cement System

Transcription

1 Installation Instructions Urethane Cement System

2 NeverStrip Self-Leveling, Textured Urethane Cement System ( Urethane Cement ) I. General Information NeverStrip Self-Leveling, Textured ( Urethane Cement ) is a three or four component, self-leveling, urethane-modified cementitious topping with silica or quartz aggregate and appropriate Grout Coat and Top Coat. This system is designed to protect concrete from chemical corrosion, abrasion, impact and thermal shock, while providing a seamless, durable high-traction floor for demanding commercial and industrial environments. 2 The NeverStrip can be a solid, opaque color using: 1) NeverStrip Urethane Cement, 2) Silica sand, 3) Chemical Resistant Epoxy Color as a Grout Coat and 4) pigmented Extreme Performance, High Solids Urethane or Chemical Resistant Epoxy as the desired top coat. Or The NeverStrip can use: 1) Urethane Cement, 2) blended decorative quartz, 3) Chemical Resistant Epoxy Clear as a Grout Coat and 4) clear Extreme Performance, High Solids Urethane or Chemical Resistant Epoxy as the desired clear top coat. When using decorative quartz, a second broadcast is highly recommended to ensure adequate color hiding. A single broadcast of decorative quartz may result in thin spots, which can show as a color tone variation due to visibility of the NeverStrip Urethane Cement. A 4 cove base may be applied to further provide a seamless flooring system. Go to NeverStrip Cove Base at: II. Surface Preparation Surface preparation is the most critical portion of any successful resinous flooring system application. All substrates must be properly prepared to a minimum Concrete Surface Profile (CSP-3), as outlined in NeverStrip s Concrete Preparation at: com/technical-documents.htm. Specific attention should be paid to the following: A. Concrete Placement B. Curing and Finishing Techniques of the Concrete Substrate C. Age of Concrete D. Previous Contamination of the Substrate E. Present Condition of the Substrate Temperature and humidity conditions of the area to receive the flooring system should be checked. An optimum room temperature of 75ºF with a minimum slab temperature of 60ºF is recommended for proper cure of the resin flooring system. Cooler temperatures will slow cure times. System may be installed with integral cove base.

3 Quarry Tile Surface CAUTION: It is recommended the NeverStrip Self-Leveling, Textured Urethane Cement System be applied directly to properly prepared concrete with RH moisture levels of less than 90%. The application of this system directly onto a quarry tile floor must be done with full awareness of the risks and with all due caution and diligence, as follows: 1) The strong bond of the urethane cement system may cause possible cracking of the quarry tiles and/or may cause quarry tiles to lose adhesion. 2) Quarry tile should be evaluated for proper adhesion prior to the installation of the and replacements made as necessary with proper adhesive. 3 Floor must be cleaned with an aggressive degreaser cleaner designed to remove grease in the environment in question, such as a commercial kitchen. Different environments may demand alternative degreasing type cleaners and other materials to remove the grease. This process may require multiple passes. Quarry tile must be prepped with course diamonds (24-36 grit) and appropriate machinery to remove material from the quarry tile and prepare a rough surface. The objective is Not to just achieve a moderate scratch pattern. The objective is to deglaze the Quarry Tile and create a rough profile to achieve a positive bond. Use smaller 7 hand held machine to prepare tile surfaces along baseboards and tight areas. All equipment and other tables, etc. should be removed from the space to insure proper floor preparation and installation of the urethane cement system. III. Special Conditions Do not apply in temperatures below 45 F or above 85 F, or if relative humidity is above 85%. Do not apply to sand-cement screeds (tile setting bed mortars), asphaltic substrates, glazed tile or brick (unless glaze is mechanically abraded), copper, aluminum, softwood, or existing coatings of epoxy* or urethane*. Do not apply to wet concrete (i.e., surface wet to the touch) or to polymer modified concrete with moisture content above 10%. Do not apply to concrete if air temperature is within 5 F of dew point. Do not featheredge application or mix material by hand. Do not apply to concrete with an RH reading of 90% or higher. *Note: Thoroughly sand the coatings for application over existing well-bonded epoxy or urethane coatings. Apply NeverStrip Concrete Primer 100 at 10-mils, broadcast 30-mesh sand/quartz to excess. Allow primer to cure, sweep/vacuum excess sand, proceed with installation of NeverStrip Self-Leveling.

4 IV. Material Quantities A. Guideline System Requirements on Concrete for 1000 ft² NeverStrip Self Leveling with Quartz or Silica Sand (3/16-1/4 ) Qty./1000 ft² 1. NeverStrip Concrete Primer 100 optional, 8-10 kits (Broadcast silica or quartz onto primer, 100 lbs.) 2. NeverStrip Self-Leveling Urethane Cement (neutral color) kits (A, B and C) 3. Broadcast 30-mesh Silica Sand or Decorative Colored Quartz Granules, 500 pounds 4. NeverStrip Chemical Resistant Epoxy, gallons, Clear or Color (Use Clear for Decorative Quartz and Color for Silica Sand System) 5. Optional, second broadcast of decorative quartz at 500 pounds 6. Topcoat options include: NeverStrip Extreme Performance, 6-8 gallons or NeverStrip s High Solids Urethane, 2 gallons or NeverStrip Chemical Resistant Epoxy, 6 gallons Optional Non-Slip Additives for additional texture in very wet areas: a) NeverStrip Grip Aggregate (Aluminum Oxide) (80 mesh) 50 pounds b) NeverStrip Resin Grip Aggregate (40/60 mesh) 1 gallon 4 V. Installation Note: If using NeverStrip Concrete Primer 100, lightly broadcast 30 mesh sand or colored quartz onto primer at rate of 100-lbs./1000 ft². Mechanical mixing is required. A ten-gallon KOL mixer and paddle is recommended or a ¾ horsepower drill and Jiffy or helical mixer may also be used with a 5-gallon pail. 1. Mixing NeverStrip Self Leveling, Textured Urethane Cement (Parts A, B and C) a. Add Part A and Part B, use mixer and blend for 30 seconds. Important: Do not over mix or working time will be significantly reduced. b. Add Part C slowly to the mix (while mixer is running) and allow to blend for 1-2 minutes. Only mix as long as needed to completely wet-out aggregate or working time will be significantly reduced. Be sure to wet-out all parts of the mix, scraping sides and bottom of mixer during mixing. All powder must be uniformly blended with no visible lumps of dry powder. Mixing bucket and mixer or blades should be scraped out thoroughly and cleaned with solvent (acetone, MEK or xylene) every few batches or working time on subsequent batches will be shortened. If mixing in a plastic bucket, dispose of bucket after every 2 mixes and replace with a clean bucket. Important: Do not over mix or working time will be significantly reduced. Set up mixing station as near to the work area as possible. Exothermic heat will be generated and flash setting may occur if material remains in the pail too long. Do not mix more than can be used in 10 minutes.

5 2. Application of NeverStrip Urethane Cement a. Place mixture on floor and spread with a gauged straight edge (gauge rake set 3/16 to 1/4, slightly higher than desired thickness of 1/8 to 3/16 ). Leave a wet line or puddle of material between batches to avoid knit-lines in the finished system. [Optional, If a double quartz broadcast system is to be applied over the, the visibility of any knit lines should be minimal. Be sure to grind out any ridges or lumps that form where material from adjacent batches may overlap after the first broadcast has cured, prior to starting second broadcast procedure.] Maximum working life is 15 minutes at 70 F, less than 10 minutes at 80+ F. To modestly extend the working life in very hot temperatures, cool the resin and aggregate components prior to use. If pigment pack is to be used, add to urethane resin during mixing. 5 b. Back-roll the surface lightly with a Spiny roller (13/16 spikes), while material is still wet. The Spike roller helps to level out the Urethane Cement material and to release entrapped air in the cement. To minimize marks in the finished system, the applicator should wear spiked shoes while walking on wet material. Keep roller cleaned with isopropyl alcohol. c. Broadcast Silica or Sand (30 mesh) or Decorative Colored Quartz Granules onto the wet floor system until the surface of the system appears dry. Be careful not to clump the material or produce high spots. Approximately pounds will be needed for 1000 ft² of flooring. Allow Urethane Cement to cure a minimum 8 hours. Sweep and vacuum excess granules. Grind to reduce any significant uneven areas. 3. Mixing Chemical Resistant Epoxy (Clear or Color) a. Drill each component prior to mixing b. Mix two (2) parts by volume of Part A with one (1) part by volume of Part B (Hardener) for three minutes with a low speed electric drill with mixing paddle. Add pigment pack for solid colored systems (not decorative quartz) after mixing A and B for one minute and continue mixing for remaining two minutes. c. Mix only the amount of material that can be immediately poured out in ribbons, spread with a flat squeegee and back rolled within minutes. 4. Application of Chemical Resistant Epoxy (Grout Coat Color or Clear Coat) a. Immediately pour mixed material onto floor in strips and spread at a rate of ft² per gallon (depending on desired finish texture) using a flat squeegee or trowel, followed with back rolling. If using a flat squeegee or trowel, it is recom mended that the material be lightly back rolled with a medium-nap roller to smooth and level any tails or ridges. b. To minimize marks in finished system, the applicator should wear spiked shoes, while walking on wet material. c. Allow the material to level for approximately 10 minutes. Termination points at breaks and at the end of the day should be made at doorways, expansion joints, etc.

6 Note: The Chemical Resistant Epoxy comes in Clear or Color (using NeverStrip Pigment Packs or from the factory). When using decorative quartz, a second broadcast is highly recommended to ensure adequate color hiding. A single broadcast of decorative quartz may result in thin spots, which can show as a color tone variation due to visibility of the NeverStrip Urethane Cement. d. Broadcast to excess (2nd broadcast). Broadcast colored quartz granules into the wet epoxy until the surface of the system appears dry. Be careful not to clump the material or produce high spots. Approximately 500 pounds of quartz per broadcast will be needed for 1000 ft² of flooring. Remember to only walk on the wet surface while wearing spiked shoes!!! 6 Do not walk on floor after broadcasting. e. Allow the seeded floor to cure overnight. Sweep excess quartz with a stiff bristled broom followed with power vacuum. A light sanding will aid in achieving a uniform sanded surface. 5. Application of Topcoat. The sealing of a floor should be performed over the entire area receiving the system. The coverage rate and number of the applied grout and topcoats dictate the final texture of the floor. Higher coverage rates will yield rougher textures. Coverage rates outlined will yield a medium texture. a. For applications using Silica Sand, mix NeverStrip Extreme Performance Part A and B for one minute with an electric drill. Add Part C and desired pigment pack (to match the Grout Coat Color) and mix for an additional two minutes b. For applications using decorative quartz, mix NeverStrip Extreme Performance Part A and B for one minute with an electric drill. Add Part C and desired and mix for an additional two minutes c. Spread the Extreme Performance at a rate of approximately 160 ft² per gallon using a flat trowel or squeegee. d. Lightly back-roll the material with a short nap roller to help spread the material and eliminate squeegee marks. e. Allow material to cure at least 2-4 hours at 70 degrees F. for light foot/cart traffic and 24-hours for forklift or vehicle traffic. f. Optional alternative topcoat is NeverStrip High Solids Urethane in Color or Clear for Silica Sand or decorative quartz system, respectively. Add pigment pack in the field for colored system. Use ¼ nap woven roller for application. High Solids Urethane comes in Gloss or Satin.

7 Terminations, Crack Repair, Joint Treatments: a. All free edges (perimeters, terminations adjoining cove base or control/expansion joints, or along gutters or drains) should ideally be keyed in to provide extra anchor to distribute mechanical and thermal stresses. This is optional depending on the application, exposure to severe thermal shock, etc. but is very important around drains or adjoining other floor finishes. This can be achieved using a chipping hammer or saw. b. All expansion joints must be exposed through the system. Control joints (saw cuts) and cold joints should also ideally be exposed through the Urethane Cement System but may be overlaid if the facility owner accepts that future telegraphing cracks may develop if expansion/contraction movement occurs in the substrate joint. To overlay a control joint, fill with rigid epoxy crack filler and follow with 12 wide fiberglass cloth reinforcement. 7 c. Cracks: Route cracks larger than 1/16 and fill with rigid epoxy crack filler and reinforce with 12 wide fiberglass cloth. Customer Service: For Hazardous Materials (or Dangerous Goods) Incident: Spill, Leak, Fire, Exposure, or Accident Call CHEMTREC, Day or Night USA and Canada: NeverStrip, LLC