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Industrial Epoxy Flooring

" Performance Flooring "

TC-200 Broadcast Floor System

Do-it-Yourself
Installation Procedures

 

Precision Epoxy Products
a division of : Rock Art, Ltd.
4279 Midway Drive
Douglasville, Georgia 30134
Phone : (770) 489-0340

 

 

    Surface preparation is always an important aspect of a coating's application and should be given the time and effort needed to complete properly. Ideally, new concrete is the easiest and most predictable application environment for applying the TC-200 Broadcast Floor System; however, any floor can receive this system with proper substrate preparation. Basically the substrate should be clean, dry and free of oils, grease, silicones, waxes, existing coatings, etc. These contaminants are generally saturated into the pours of the substrate and can prevent penetration, limit proper bonding and/or cause 'Fish Eyeing' of the epoxy primer. Due to the variety of situations that can exist with older substrates and the numerous ways to deal with these situations, Precision Epoxy should be consulted to discuss your individual project to determine the best course of action. For the purpose of these installation procedures, it is assumed that we are dealing with a new construction project shop. For our 16 Standard Colors available see Color Chart.

1st Day

  1. A location is selected to set-up your epoxy mixing shop. The mixing shop should be as close to the work area as possible to stage and mix epoxies, to access application tools and to prepare and clean up as needed. The shop should be in a controlled environment and large enough to spread out materials and tools and to accommodate crew members. Plastic and cardboard should be laid down first as a sub-floor to protect existing flooring from spills and/or splatter. Ideally there will be an office or adjoining room that is going to be carpeted or tiled later that can be used. In some cases a trailer parked outside an access door can be used. Your mixing shop should not be set-up outside and exposed to the elements.

  2. The entire area is sanded using a rotary floor buffer with a sanding attachment and a 20-3 grit paper. This will knock down concrete protrusions, trowel marks, spackle splatter, residue, etc. The sanding is not intended to polish the concrete but to smooth down flaws and profile the concrete.

  3. All debris and dust created by sanding is removed. Generally this is accomplished by sweeping and pick-up of the bulk debris followed by a detailed vacuuming.

  4. The concrete is closely inspected and all spalling, depressions, holes and chips along with stress fractures, cold joints or shrinkage cracks are filled with the SG-25 Epoxy System. This is done with a margin trowel, spackling blade or putty knife. The SG-25 should be tooled as smooth as possible to avoid additional sanding later. In some deeper fills, sagging can occur and a second application may be necessary. Correcting these flaws will add to the cosmetic value that the TC-200 Floor System has to offer. The SG-25 Epoxy System has a mix ratio of 1:1 / A:B by volume and no more material than can be applied in 30 minutes should be mixed at a time.

  5. Roll up doors will need to have plastic affixed and secured in a fashion that resembles one half of a tent to allow the doors to remain open in order to coat the shop concrete floor that extends the 8 to 12 inches outside the door to the cold joint seam where the driveway begins. The roll up doors will not be able to be closed until the epoxy has cured and the plastic should be placed so that it keeps out weather, blowing debris, bugs, etc. Ideally your doors will hinge when rolled up allowing for the plastic to be pulled through the lower panel slots when the door is raised. Then the plastic will be secure when the door is lowered and the panel slot closes. This will keep the plastic in place without tape or fasteners while the door has enough gap at the bottom to work epoxy coating under doors. The plastic is then pulled out at an angle and weighed down in place with 2x4's and concrete blocks, for example, on the driveway. For other than roll up doors, alternative methods of protection will need to be implemented.

2nd Day

  1. An inspection of the SG-25 Epoxy filler work is made to determine if it has been tooled smoothly or if sanding of these areas is deemed necessary. If sanding down any rough toolings is needed, this can be performed using a 7" hand disc grinder or the rotary floor buffer with sanding attachment. All grinding mess will then require vacuuming to clean up.

  2. Now you are ready to apply the primer coat of the TC-200 Broadcast Floor System. The IG-100 Epoxy is used as a flexible penetrating primer because of its excellent elongation properties, elasteric memory, low viscosity, extended pot life and open time. These elements of the IG-100 Epoxy combine to give this system outstanding saturation qualities into the concrete and the ability to absorb thermal shock. The IG-100 Epoxy has a mix ratio of 1:1 / A:B by volume and although this system has an extended pot life, no more material than can be applied in 30 minutes should be mixed at a time (see recommended batch sizes below). The IG-100 Epoxy is applied by brush and roller at a rate of 250 square feet per gallon. Epoxy is applied using a cut-in technique by brush at corners, walls, support post and all areas where a roller will not reach. The remainder of the floor is roller applied. To gauge proper application coverage, you should be applying the IG-100 with one dip of the roller in material being applied as one roller stripe on the floor 5 to 6 feet long.

  3. Different degrees of penetration are possible depending on the porosity of the concrete. The finished application of IG-100 Epoxy will most likely have a splotchy appearance with glassy areas (where minimum saturation occurred) and textured areas (where maximum saturation occurred).

  4. The IG-100 will have a slight tacky feel the next day when the second step is applied.

3rd Day

  1. The silica sand to be used during this step should be readied and staged in a convenient location close by, but out of the way, for easy and quick access when ready to use.

  2. The 2nd coat is applied over the primer coat with no additional preparation needed. The primer coat is too soft at this point to be sanded; however, any flaws in the concrete that were missed during the 1st day will be visible in the gloss finish of the primer coat. These flaws can be filled with the SG-25 Epoxy at this time and tooled smooth. The SG-25 should be allowed to cure overnight before proceeding. If only a minimum of SG-25 is applied, you can proceed with the application of the 2nd coat using great care not to step in the uncured SG-25.

  3. The FS-190 Epoxy System is used for the 2nd coat and has a mix ratio of 2:1 / A:B by volume and is applied at a rate of 160 square feet per gallon. It is applied by brush and roller and no more material than can be applied in 25 minutes should be mixed at a time (see recommended batch sizes below). Do not add solvent to this coat. To gauge proper application coverage, you should be applying the FS-190 with one dip of the roller in material being applied as one roller stripe on the floor 4 to 5 feet long.

  4. After application to concrete, the FS-190 Epoxy is allowed time to 'lay-out' or flow smooth to level out roller ridges and lap marks. This will generally take 15 to 30 minutes depending on the application temperature in your shop. Broadcasting sand without allowing the FS-190 to 'lay-out' will create unnecessary roughness in the floor that will have to be sanded smooth later.

  5. Then while the FS-190 Epoxy is in it's 'open time', generally 1 to 2 hours depending on the application temperature in your shop, you broadcast a clean, dry, fine (60 mesh or similar size) silica sand into the uncured FS-190 Epoxy. Wearing spiked shoes, the applicator is able to walkout on the freshly applied epoxy without disrupting the product's film integrity. Care should be taken not to drag or skate the spikes in the epoxy in a manner that leaves grooves. The grooves will not have time to flow closed and should be brushed smooth with a cut-in brush before the sand is broadcast over them, otherwise, the sand will lock them in creating additional work to correct later. Walking in spiked shoes can be very slippery; you must be paying attention during this phase of the work.

  6. Sand is broadcast solid and heavy enough to achieve a total dry sand appearance over the uncured epoxy; this assures uniform saturation and coverage. Normal application coverage for the sand is 135 square feet per 100 lbs. The silica sand is broadcast much like 'feeding the chickens', using small manageable buckets. These broadcast buckets are best refilled by a second crew member in order to keep the operation flowing and for not having to walk off the work area in the spiked shoes until this phase of the work is completed.

  7. Avoid walking on the areas of the floor after sand has been applied in your spiked shoes; it can leave marks that might need corrective measures later.

  8. This is the longest and most labor intensive step of the entire TC-200 Broadcast Floor System as well as one of the most important. The sand gives this floor system its outstanding compressive strength and its structural thickness that without it would take 10 to 12 coats of epoxy to achieve.

4th Day

  1. The excess sand that did not bond into the FS-190 Epoxy is picked up with a broom and shovel. You will be picking up between one half to two thirds of the sand you broadcast in the previous step. This sand can be saved and reused on future projects. If you are doing your floor in sections, you can reuse this sand on the next section and will not need to purchase as much sand for the overall project. Remember to take care and make sure the sand is kept clean and dry if you are planning to reuse it.

  2. The floor is then sanded with a rotary floor buffer and sanding attachment using 20-3 1/2 grit paper to smooth any imperfections and partially bonded grains of sand. This sanding process is generally quick and fairly light while using a more aggressive technique on any rough or flawed areas.

  3. After sanding is completed, sweep and pick-up the bulk of the debris and discard. None of this sand is reusable in the flooring application.

  4. The floor is then detailed vacuumed to complete the cleaning process. Sweeping or blowing alone will not be adequate to clean the floor properly.

  5. The first color coat of TC-200 Epoxy is now applied by brush and roller at a rate of 125 square feet per gallon. No more material than can be applied in 25 minutes should be mixed at a time (see recommended batch sizes below). You should be applying the TC-200 with one dip of the roller in material being applied as one roller stripe on the floor 3 to 4 feet long. The TC-200 Epoxy is mixed at a ratio of 2:1 / A:B by volume.
    This coat can also be applied using the squeegee and back roll method which is generally faster but uses slightly more material to complete. Consult with Precision Epoxy for more information on this procedure.

  6. This will complete the structural body of the floor system. The coat will leave the floor with a combination of glassy and textured areas. The glassy areas are low spots where the TC-200 puddles and completely fills the sand texture. The textured areas are high spots where the TC-200 has run off and not completely filled the sand.

  7. Remember, using proper roller technique, you are trying to fill the sand and make the TC-200 look glassy as you apply the material and work your way out. The splotchy look will not show up till later.

  8. Approximately two thirds of the total TC-200 Epoxy purchased for your project is used on this coat.

5th Day

  1. The floor is inspected once again for any flaws that might benefit from filling to eliminate prior to the final top coat. If such areas are found, then mix up a special batch as needed using the TC-200 Part 'A' and the SG-25 Part 'B' at a mix ratio of 1:1 / A:B by volume. This will give you a paste material the same color as the floor that can be tooled in smoothly to correct flaws. This will eliminate any off color bleed through in the top coat that the SG-25 material alone can create. Remember this process will need to cure overnight before the final top coat can be applied.

  2. The floor is sanded with the rotary floor buffer and sanding attachment using the 20-3 grit paper to smooth any flaws and profile for the cosmetic top coat. The sanding of the floor at this point will not create much debris and can be vacuumed to clean.

  3. After vacuuming, the floor is then tack-ragged with denatured alcohol to remove any fine dust particles, moisture, humidity or possible contaminates. Tack-ragging is optional but highly recommended. Tack-ragging should be performed in such a fashion to clean off the floor and not just smear around.

  4. Now you are ready to apply the cosmetic top coat of the floor system. The TC-200 Epoxy is applied at a rate of 225 square feet per gallon and mixed at a ratio of 2:1 / A:B by volume. It is recommended that Xylene or Xylol solvent be added at 8% to 17% by volume to the TC-200 on a per batch basis to extend the product's pot life and lower its viscosity which will make it flow out better (see recommended batch sizes below). By staying within the recommended limits, the added solvent will evaporate out during the curing cycle and maintain the TC-200's 100% solids content.

  5. Being the final top coat of the system, the TC-200 is applied by brush and a special shed-resistance roller to minimize nap hairs in the finish. You should be applying the TC-200 with one dip of the roller in material being applied as one roller stripe on the floor 6 to 8 feet long.
    You can also apply the final coat using an airless sprayer; however, in most cases, the additional work involved with taping and cover up makes this type of application unfeasible. Furthermore, in most cases, using an airless sprayer with epoxies should only be attempted by an experienced professional.

  6. The completed TC-200 Broadcast Floor System will accept foot traffic in 24 to 48 hours and automobile or fork lift traffic in 5 to 7 days depending on the application temperatures.

Summary

    You must realize that a good job is the result of careful attention to detail, following the products mix ratios and recommended batch sizes and the following of the application instructions. Viewing of the TC-200 instructional video and all the products technical bulletins is recommended to fully understand the handling, measuring, mixing, application and clean up involved when using all the epoxy systems required during the TC-200 Broadcast Floor System's installation.

    Expansion joints are dealt with in different ways depending on the type you may have. Consult with Precision Epoxy for options for your situation. If your expansion joints are saw cuts, they should be at least one half the thickness of your concrete slab to be effective. A quick and cosmetic way to finish saw cut joints is to apply the floor system up to the saw cuts without filling them with epoxy. This reduces your floor to smaller sections versus one large area making application more manageable. When flooring installation is completed, purchase a roll of " vacuum line at any auto parts store and press the vacuum line flush into the " saw cuts. This gives the floor a very nice appearance while being very functional. It keeps debris out of the saw cuts while allowing the expansion joint to expand and contract as it is designed to do. It also allows any ground moisture migration a point of release if necessary.

Do Not :
1) Alter any product's mix ratio for any reason.
2) Apply any coat beyond it's recommended coverage.
3) Wear work shoes or use power cords with oil or grease on them.

    When renting a floor buffer for sanding, always check the underside housing for grease or oily residue before accepting the unit for use. Some older units can have wore grease seals that allow bearing grease to be slung out during operation onto floor. Contamination on housing surface will generally be dust covered and not easily visible, rubbing surface with finger will better reveal contaminants. When sanding between coats, should sand paper become gummed up easily, additional curing time will be needed before proceeding. The TC-200 Broadcast Floor System can be applied at any temperature; however, at cooler application temperatures, additional curing time between coats must be allowed. The 4-step floor system can be applied in four consecutive days, four consecutive weekends or whatever time frame best fits your schedule. All tools and equipment needed for the floor system installation are available on the  Flooring Shop Check List .

To review the Dust Collection Products we use and sell go to Dust Collection Products.


Recommended Batch Sizes :
(for one 9 inch roller set-up)

Prep work:    SG-25 Epoxy    Mix @ 1:1 / A:B as needed

1st Coat:    IG-100 Epoxy (Ratio 1:1 / A:B)    Mix 8 cups Part 'A' to 8 cups Part 'B'

2nd Coat:    FS-190 Epoxy (Ratio 2:1 / A:B)    Mix 8 cups Part 'A' to 4 cups Part 'B'

3rd Coat:    TC-200 Epoxy (Ratio 2:1 / A:B)    Mix 8 cups Part 'A' to 4 cups Part 'B'

4th Coat:    TC-200 Epoxy (Ratio 2:1 / A:B)    Mix 8 cups Part 'A' to 4 cups Part 'B'
                                                           with 2 cups of Xylene

Note: (1 cup = 8 oz.) Precalibrated measuring sets available
Stir all batches with a drill and mix blade for a timed 2 minutes (not guessing)
Avoid whipping air into material when mixing
Small batches of SG-25 can be mixed by hand
Smaller batches than above can be mixed when needed using the proper mix ratio.


Recommended Batch Sizes :
(for one 18 inch roller set-up)

Prep work:    SG-25 Epoxy    Mix @ 1:1 / A:B as needed

1st Coat:    IG-100 Epoxy (Ratio 1:1 / A:B)    Mix 1.25 gallon Part 'A' to 1.25 gallon Part 'B'

2nd Coat:    FS-190 Epoxy (Ratio 2:1 / A:B)    Mix 1.25 gallon Part 'A' to 5/8 gallon Part 'B'

3rd Coat:    TC-200 Epoxy (Ratio 2:1 / A:B)    Mix 1.25 gallon Part 'A' to 5/8 gallon Part 'B'

4th Coat:    TC-200 Epoxy (Ratio 2:1 / A:B)    Mix 1.25 gallon Part 'A' to 5/8 gallon Part 'B'
                                                             with 5 cups of Xylene

Note: Precalibrated measuring sets available
Stir all batches with a drill and mix blade for a timed 2 minutes (not guessing)
Avoid whipping air into material when mixing
Small batches of SG-25 can be mixed by hand
Smaller batches than above can be mixed when needed using the proper mix ratio.


     An Epoxy's solid state properties can only be achieved by thorough mixing of Parts 'A' and 'B' at the proper mix ratio. Higher application temperatures will accelerate reaction time reducing pot life, open time and cure time while making the viscosity of the product thinner. Lower application temperatures will make reaction time sluggish extending pot life, open time and cure time while increasing the viscosity of the product.

    Every reasonable precaution is taken in the manufacture of all products and compiling of data to assure that they comply with ROCK ART'S exacting standards. Reliable tests and field experience of these products indicate there utility as described herein. The suitability of a product for an intended use shall be solely up to and the ultimate responsibility of the user/purchaser of that product. You must determine your reliability as an applicator for your specific application. We are not responsible if a product should be used by the user/purchaser in a manner to infringe any patent held by others.

    We assume no liability for damages of any kind and no guarantee of results using these products or data that is given because every possible variation in the method of their use or conditions under which they are applied cannot be anticipated.

User accepts product "AS IS" and without warranties, expressed or implied.

For our 16 Standard Colors available see Color Chart.

See  Flooring Shop Check List  and  Shop Flooring Order Form  for additional information.



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Copyright 1970 - 2016 / Rock Art, Ltd.

Precision Epoxy Products
4279 Midway Drive
Douglasville, Georgia 30134
Mike Ramy
(770) 489-0340
mramy@netzero.net

Notice: All Photographs and Text in this web-site are Copyrighted and are the sole possession of Rock Art, Ltd.
Any unauthorized use is strictly prohibited by law. Violations will be treated appropriately.

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