Shop and Garage Flooring
" Performance Flooring "™
TC-200 Broadcast Floor
Professional 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
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.
The entire area is sanded using a rotary floor
buffer with a sanding attachment and a 20-3 1/2 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.
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.
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.
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.
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.
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.
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).
The IG-100 will have a slight tacky feel the next day when
the second step is applied.
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.
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.
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.
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.
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
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.
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.
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.
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.
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
After sanding is completed, sweep and pick-up the bulk of
the debris and discard. None of this sand is reusable in the flooring
The floor is then detailed vacuumed to complete the cleaning
process. Sweeping or blowing alone will not be adequate to clean the floor
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.
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.
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.
Approximately two thirds of the total
TC-200 Epoxy purchased for your project is used on this coat.
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.
The floor is sanded with the rotary floor buffer and sanding
attachment using the 20-3 1/2 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.
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.
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.
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
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.
You must realize that a good job is the result of careful attention to
detail from substrate preparation to the final application coat. 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 ¼" vacuum line at
any auto parts store and press the vacuum line flush into the ¼" 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.
To review the Dust Collection Products we use
and sell go to Dust Collection Products.
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
installations are honored by a one year materials and labor warranty. The
condition of the existing concrete substrate will be analyzed and the
appropriate preparation technique will be determined and applied. Existing
expansion joints and stress fractures that our floors have to be applied over
will be prepared to minimize the possibility of them telegraphing through or
cracking the epoxy flooring. No warranty is however expressed or implied
should this situation occur. There is furthermore no warranty expressed or
implied should the epoxy floor be cracked or lift due to settling or movement
of the concrete substrate or due to seismic activity. No warranty is expressed
or implied for lifting of the floor plate due to ground moisture migration.
For our 16 Standard Colors
available see Color