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Epoxy Surface Plate
  
" When Accuracy Matters "


Installation Procedures


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



The Perfect Set-up Starts with
the most Accurate Surface Plate Available

 



The Pro Epoxy Surface Plate Professionally Installed

If you have ever visited some of the NASCAR shops in the Charlotte, North Carolina area, then you have most likely seen one of our Pro Epoxy Surface Plates in action. The Pro Plate System is our top of the line plate with all the features our professional installations have to offer. The following is one of our typical installations of our most popular 12' x 20' Surface Plate. Larger or smaller plate sizes might require or allow for variations in procedures and scheduling. All our products are true 2-component, 100% solids, zero VOC 'Old School' epoxies.

1st Day:

  1. Select location in shop for plate and clear out to expose floor allowing for extra space for adjoining epoxy mixing shop. This will basically be two car stalls or similar size area. Plate location is determined by several factors such as accessibility, expansion joints in sub-floor, building's electrical system, etc. Remember, your Epoxy Surface Plate is a very important set-up tool that just happens to be on the floor. It will be a focal point of your shop and a much used area. Plan on work benches, tool boxes and storage areas for all your other set-up tools to compliment your new plate.

  2. Measure and mark dimensions on floor at corners of plate and chalk lines to establish the plate perimeter and the access ramp perimeter. This will show the plate lay-out in detail and its location can be finalized. Then using 2" masking tape we mask off the outer chalk line of the access ramp perimeter.

  3. Using an EDCO CPM-8 - 8" Scarifier machine ( learn more at  www.edcoinc.com ) we prepare the sub-strate within our outer access ramp tape line by cleaning, removing existing coatings and profiling the concrete. Our scarifier is equipped with a vacuum attachment making the procedure virtually dust free.

  4. The area is then thoroughly vacuumed and cleaned. We unload our trailer and set up our work shop area adjoining the plate area.

  1. Now the chalk lines for the plate surface perimeter must be reestablished allowing for an additional one inch of width and length.

  2. A special fiberglass treatment is applied to any stress fractures or expansion joints in the concrete within the plate area to minimize the chance of them telegraphing through the surface plate at some point in the future. Most expansion joint voids or larger stress cracks are pre filled with either the SG-25 or FG-100 epoxy gel systems prior to fiberglassing.

  3. We roller apply our IG-100 penetrating primer system to prepared concrete sub-strate within the plate chalk lines making sure to lock in the chalk lines with the primer. The access ramp area will be primed during ramp installation process. The IG-100 epoxy is designed with a slow rate of cure to allow for maximum penetration and has a tensile elongation that absorbs thermal movement between the concrete and the surface plate. The IG-100 primer also seals the concrete to eliminate air bubbles that would be created if the first pour of the plate installation was applied onto bare concrete.

  4. The area is roped off to foot traffic with survey tape and the primer allowed to cure overnight.

2nd Day:

  1. The temporary 'L' angle aluminum form work is prepared for mounting by applying a thin film of form release agent to the outer bottom of the form where it meets the floor.

  2. Our FP-85 Part 'A' base coat drum of epoxy resin is positioned, opened and started stirring. We attach a 55 gallon drum heater to bring it up to our application temperature of 90 to 100 degrees.

  3. The forms are then mounted to the concrete floor using the locked in chalk lines as a guide. Form work is attached by hammer drilling 3/16th inch holes ever 16 inches, inserting plastic anchors and screwing into place through the base of the 'L' angle.

  4. Using 2" duct tape we waterproof the form work by taping 1/2" onto the floor and 1 1/2" up the inside of the 'L' angle. Our IG-100 primer allows for the tape to make a good seal to the concrete. The area must be 'watertight' to contain the fluid self leveling epoxy.

  1. The concrete is marked within the ramp area down the length of the plate to indicate where the predetermined number of batches are to be poured from side to side.

  2. The batches are then made ready by pre-measuring our heated resin into our 5 gallon mixing buckets.

  3. Now we are ready for our base coat pour of Floor Plate Epoxy FP-85 . We add our Part 'B' hardener component and stir for four minutes with our special mix blade and drill motor. Each batch is immediately poured into framed area at location marks to aid in leveling. The base coat is generally poured to a depth of 1/4" at a rate of 6.4 square feet per gallon. This coat will establish the relationship of the level surface plate plane to your uneven concrete floor.

  4. Once the base coat is poured, epoxy can be moved around to aid in leveling using a 24" gauge rake. This must be done prior to the start of the curing cycle.

  5. The area is roped off to foot traffic with survey tape and the base coat allowed to cure overnight.

  6. Note : The FP-85 Epoxy System now has special de-air additives allowing them to release on their own entrapped air bubbles created during measuring, mixing and pouring. This eliminates the need for torching this coat.

3rd Day:

  1. At this point it must be determined if the floor area will be leveled to the desired results with the following Color Coat and Clear Coat pours or if the concrete substrate is going to require additional pours to level due to it being uneven beyond normal requirements. If needed, additional pour or pours are made as needed in preparation for the color coat pour.

  2. If the base coat is level enough to proceed, we are ready for our color coat pour and the base coat is sanded using a 16" rotary floor sander with a coarse 20-31/2 grit paper. The area is vacuumed and tack ragged with denatured alcohol.

  3. Our FP-85 Part 'A' color coat drum of epoxy resin is positioned, opened and started stirring. We attach a 55 gallon drum heater to bring it up to our application temperature of 90 to 100 degrees.

  4. We now install our Grounding System copper foil tape to the base coat in a 12" grid pattern (see  Advanced Grounding System  for additional information).

  5. The plate area is again tack ragged and readied for our color coat pour.

  6. The batches are then made ready by pre-measuring our heated resin into our 5 gallon mixing buckets.

  7. The concrete is marked within the ramp area down the length of the plate to indicate where the predetermined number of batches are to be poured from side to side.

  1. Now we are ready for our color coat pour of Floor Plate Epoxy FP-85. We add our Part 'B' hardener component and stir for four minutes with our special mix blade and drill motor. Each batch is immediately poured into framed area at location marks to aid in leveling. The base coat is generally poured to a depth of 3/16" at a rate of 8.5 square feet per gallon or 1/4" at a rate of 6.4 square feet per gallon dependent on which is needed to level the plate.

  2. Once the color coat is poured, epoxy can be moved around to further aid in leveling using a 24" gauge rake. There will be less of a need for this once you master the art of pouring the epoxy evenly.

  3. The entire area is spike rolled to assure a uniform appearance between batches and with color.

  4. The area is roped off to foot traffic with survey tape and the color coat allowed to cure over night.

4th Day:

  1. At this point, we verify that the surface plate plane is level to within 2 tenths of 1% of perfect. This is very important for the final steps to work properly.

  2. Using an 8" worm drive saw with a dry cut diamond blade we are ready to cut a 1/4" deep groove around the entire perimeter creating the outer edge of our access ramp. The saw rides in a specially designed wheeled tray to keep from scratching existing floor finish and to allow for proper spacing to achieve the 6" width of the ramp. We use our temporary aluminum work as a saw guide to get as straight a cut as possible. A vacuum attachment is used in conjunction with the saw to minimize any dust.

  3. We are now ready to mount our permanent form work. 3/16" x 1/2" 'L' angle zinc strips are mechanically attached to the plate perimeter using the temporary form work as a guide. The 1/2" mounting base of the zinc strips take up the additional 1" of length and width we put into the initial pours. Mounting the permanent form work on a level surface assures that the top of the forms will also be level allowing our 3/16" thick final clear coat to fill it up perfectly.

  4. The grounding tape taps are carefully released from the temporary form work and laid out of the way back onto plate. Tape taps are fragile and must not be broken.

  5. Form mounting hardware is removed and the temporary form work is taken down.

  6. A detailing of the remaining duct tape used to seal form work is performed to clean up plate perimeter.

  1. The grounding system is completed (see  Advanced Grounding System  for additional information) with the installation of the grounding rod through the concrete sub-strate, mounting of the 1/8" copper connecting wire and the making of all our connections to the grid system.

  2. Any existing floor covering on concrete within ramp area not cleaned during initial prep work is now removed by hand so as not to damage existing floor outside the plate area.

  3. The area is roped off to foot traffic with survey tape.

5th Day:

  1. We mask off the plate perimeter using 1" masking tape and 12" paper to protect plate and reduce clean up. Taping is done on zinc form work's vertical facing and on to plate. This assures that Santex material is not inadvertently bonded at zinc seam.

  2. Next the outer perimeter of the ramp is masked off using 2" tape and applied at the saw cut.

  3. The concrete supporting the ramp is primed with the IG-100 epoxy.

  1. Access Ramp is hand troweled with our  Santex System  in a matching or contrasting color from the top of the zinc form work down into the 1/4" saw groove that we made earlier in the concrete sub-strate. By finishing our Santex material into the saw groove, we are able to maintain a structural thickness that eliminates future chipping of ramp edge from rolling equipment on and off the plate. The saw groove also gives the ramp edge, where it meets the existing floor, a nice straight 'factory' finish.

  2. Troweling of the ramp is done in a fashion that maintains a 'wet edge' at both ends to give a seamless finish when completed.

  3. The 2" masking tape on the existing floor is pulled as we proceed. The ramp receives final detailing and the existing floor is cleaned as needed.

  4. The area is roped off to foot traffic with survey tape and the ramp allowed to cure over night.

6th Day:

  1. Masking tape and paper on the plate from ramp work is now removed and plate and zinc form work are cleaned and detailed.

  2. Using a palm sander, the top of the zinc strips are sanded to clean, smooth and create a uniform width and shine.

  3. Plate surface area is vacuumed, detailed and tack ragged.

  4. Our FP-80 Part 'A' clear coat drum of epoxy resin is positioned, opened and started stirring. We attach a 55 gallon drum heater to bring it up to our application temperature of 90 to 100 degrees.

  5. The provided Race Team vinyl decal is dry mounted onto the color coat surface at the predetermined location.

  6. We prepare and apply our FS-190 Sealer Epoxy (using a 4" foam roller assembly) to the Santex Ramp. Once troweled, the Santex has a porous finish. The first sealer coat will give the ramp a splotchy appearance with glassy and textured areas. This is caused by the sealer soaking more into the thicker sections and completely filling the thinner areas.

  1. A tape measure is placed down the side of the plate on existing floor to mark batch locations.

  2. Now we are ready for our clear coat pour of Floor Plate Epoxy FP-80 . We add our Part 'B' hardener component and stir for four minutes with our special mix blade and drill motor. Each batch is immediately poured into framed area at location marks to aid in leveling. The base coat is always poured to a depth of 3/16" at a rate of 8.5 square feet per gallon. This fills our permanent form work up exactly to create a seamless transition between the plate and the ramp.

  3. Once poured, the plate is spike rolled.

  4. Unlike the base and color coats, there are no de-air additives in the clear coat formula. This means that entrained air bubbles in the pour must be released manually due to surface tension. Air bubbles come from several sources and need to be minimized as much as possible; when measuring and pouring epoxy components into containers, when stirring components and when pouring mixed epoxy into plate area. To release air, take a propane torch attached to an extension pole and wave the blue flame over the surface like a wand. This is called 'Torching' and you will be able to see the air release immediately. Proper lighting around the area will enhance reflection making the bubbles more easily seen. The epoxy is not flammable; however, should you dip the flame into the epoxy, it may leave a charred or burnt looking spot. Simply dip out dirty spot before continuing.

  5. The area is roped off to foot traffic with survey tape and the clear coat allowed to cure overnight.

7th Day:

  1. A final detailing of the plate is performed.

  2. We prepare and apply the second coat of our FS-190 Sealer Epoxy to the Santex access ramp to achieve a uniform glossy appearance.

  3. Our work shop area is broken down and loaded back into the trailer.

  4. The area is roped off to foot traffic with survey tape and the ramp sealer is allowed to cure overnight.

  1. The new Pro Epoxy Surface Plate is allowed to cure for seven days to reach its full hardness before placing a vehicle on it. Once cured, the plate will have a compressive strength of 13,500 psi with a shore hardness of 85.


Caring for your Plate:

    The Epoxy Surface Plate can be cleaned as you would any floor area in your shop. For detail cleaning, use plastic cleaners that are non-abrasive and offer anti-static and scratch resistance. (see  Advanced Grounding System  for additional information)
    The plate will show scratches over a period of time. Avoid dragging heavy and/or sharp objects over the plate surface. Plastic or rubber feet for jack stands and plastic or rubber wheels for jacks used on the plate will minimize scratching. One source for jack wheels is: Norco Industries, Inc.  (see  www.norcoind.com  for additional information) Charlotte Area Dealer: Wotco, Inc., 2708 N. Graham St, Charlotte, NC 28206, (704) 333-5441.

    Scratching of the plate is only cosmetic and will not effect it's primary use as a set-up tool. The Epoxy Surface Plate can the made to any size desired and will have an accuracy of 0.003 of an inch or better over the entire area. This accuracy is unmatched by any other type surface plate available and allows all your other set-up tools to perform properly. The Epoxy Surface Plate will never need adjusting to maintain it's accuracy. To have your Pro Epoxy Surface Plate installed by Rock Art, the cost starts at $65.00 per square foot plus travel expenses to your location for a 'Turn-Key' installation.

Do-It-Yourself Installation:

    Precision Epoxy can provide all the materials, tools and technical support to help you install your own Pro Plate or Basic Plate. The Basic Plate consist of the base coat and color coat pours. Any or all of the additional aspects of the Pro Plate are omitted making the basic plate an easier and less expensive way to achieve a level floor surface. See  Do-it-Yourself Plate  for additional information.

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



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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

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