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Transcript of Pintura TU10.2807
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COPYRIGHT SSPC: THE SOCIETY FOR PROTECTIVECOATINGS
This document and the information contained herein are copyrighted by
SSPC: The Society for Protective Coatings, 40 24th St 6th Fl, Pittsburgh PA
15222-4656 USA. All rights reserved.
You are granted the right to download an electronic file of this SSPC standard
for temporary storage on one computer for purposes of viewing and/or printing
a single copy for individual use. This copy may be may only be distributed
to other employees within your organization and only for information or
instructional purposes. Neither the electronic file nor the printed hard copymay be reproduced or distributed in any other way without the express written
permission of SSPC.
DISCLAIMER
SSPC standards, guides, specifications, and other technical documents are
developed in accordance with voluntary consensus procedures established
by SSPC Technical Committees. They are intended to represent a balance of
interests, and are believed to represent good current practice. All documentsare monitored and revised as practices improve. Suggestions for revision are
welcome.
SSPC specifically disclaims responsibility for the use or misuse of any
information contained in this document, and is not responsible for the
application, interpretation, or administration of this information. Furthermore,
no person is authorized to issue an interpretation of this information on behalf
of SSPC. The supplying of details about patented formulations, treatments,
or processes is not to be regarded as conveying any right or permission to
the user of this document to use or sell any patented invention. When it is
known that the subject matter of the text is covered by patent, such patentsare reflected in the text. Mention of specific product names does not imply
SSPC endorsement.
It should be understood by all persons using this product that SSPC does not
give any warranties, expressed or implied, nor make any representations as
to the accuracy, completeness or usefulness of the information or conclusions
contained herein, nor assume any responsibility of any nature from whatever
cause including negligence resulting from the use of this product.
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SSPC-TU 10
December 1, 2002
Editorial Revisions November 1, 2004
(PCSI) who joined the SSPC committee and participated in the
consensus review process.
This joint technology update was devel-
oped by the SSPC Unit Committee C.7.1
on Concrete Coatings and Surfacings
with the assistance of members of the
Polymer Coatings and Surfacing Institute
10-131
1. Scope and Description
This Technology Update discusses techniques and pro-
cedures to enhance performance of concrete floors by use
of resinous systems greater than 20 mils. Flooring systems
covered by this TU include: Thick film systems (>500m), self-
leveling systems, slurry systems, broadcast systems, mortar
systems, fabric-reinforced systems, spray applied systems,
and non-waterproofing and underlayment membranes. Thin-
film coatings (
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ASTM D 4541 Standard Test Method for Pull Off
Strength of Coatings Using Portable
Adhesion Testers
ASTM D 6237 Standard Guide for Painting
Inspectors (Concrete and
Masonry Substrates)
ASTM E 1907 Standard Practices for Determining
Moisture-Related Acceptability of
Concrete Floors to Receive
Moisture-Sensitive Finishes
ASTM F 1869 Standard Test Method for
Measuring Moisture Vapor Emission
Rate of Concrete Sub-floor Using
Anhydrous Calcium Chloride
3. Definitions5
Bleeding: The autogenous flow of mixing water within, or its
emergence from, newly placed concrete or mortar as caused
by the settlement of the solid materials within the mass. Alsocalled water gain. (FCC)
Broadcast Flooring: Usually neat (unfilled) resins or slurries
(aggregate filled) applied over a floor into which aggregate is
blown by specialized equipment or thrown by hand, in a raining
fashion, into the wet, uncured matrix and allowed to cure.
Broadcast to Saturation: Aggregate broadcast into a wet
matrix until the surface does not show wetness of the resinous
layers below.
Carbonation: Reaction between carbon dioxide and a hydrox-
ide or oxide to form a carbonate, especially in cement paste,mortar, or concrete. The reaction with calcium compounds to
produce calcium carbonate. (FCC)
Capillary space: Microscopic channels on concrete small
enough to draw liquid water through to be adsorbed on the
inner surface. (FCC)
Hydration (of Cement): The reaction of water with the
calcium silicate, aluminate, or aluminum/ferrite components
of fine Portland cement grains necessary for the setting and
curing of concrete. Hydration results in the formation of calcium
hydroxide and colloidal gels that occupy a larger volume than
the original cement.
Keyed (Key in): The process of removing the concrete sub-
strate in order to create a durable termination border for a fluid-
applied flooring system.
Lap Length: Thelength of overlapping of steel rein-
forcing bars.
Planarity:The general evenness of a substrate in an intended
dimension. Planarity should not be confused with levelness. A
sloped area, for example, should be in plane, without low or
high spots, but is not level.
Pozzolan:A siliceous or siliceous and aluminous material, which
in itself possesses little or no cementitious value but will, in a
finely divided form, and in the presence of moisture, chemically
react with calcium hydroxide at ordinary temperatures to form
compounds possessing cementitious properties. (FCC)
Recoat Time: The amount of time required for a coating, slurry
or mortar to dry or cure before a subsequent coat can be ap-
plied successfully.
Slump:A measure of the consistency of freshly mixed concrete,
mortar, or stucco equal to the subsidence measured for the
nearest 1/4 inch (6 mm) of the molded specimen immediately
after removing the slump cone. (FCC)
Slurry Floor: Generally 100% solids or zero VOC chemi-
cally cured resins, incorporating use of inert fillers or powders,
producing a flowable, but not necessarily self-leveling mixture.
Slurry floor materials are usually troweled to the thickness of
the largest aggregate in the material.
Resin: General term applied to a wide variety of polymeric
products, which may be natural or synthetic. They may
vary widely in color. In a broad sense, this term is used to
designate any polymer that is a basic binder material for coat-ings and plastics.
Self-Leveling Flooring: Resinous or polymer-cementitious
based materials that tend to flow out when applied over a floor,
seeking its own level. Self-leveling systems generally require
built-up termination strips as opposed to key-in terminations
for stopping points.
Skim Coat:A thin layer of resin- or cement-based mortar used
to smooth surface irregularities. Usually edges are feather-edged
without the use of keyed terminations.
Sloping Correction: 1) An adjustment applied to a distancemeasured on a slope to reduce it to a horizontal distance be-
tween the vertical lines through its end points.2) The process
of installing a given pitch to a surface.
Soluble Alkali Ions: Substances that form charged hydroxide
bases that dissolve in water.
4 ASTM International, 100 Barr Harbor Drive, West Cohshohocken, PA 19428-2959.(http://www.astm.org).5 Definitions followed by (FCC) were taken from Fundamentals of Coating Concrete. The remaining definitions were developed by the SSPC
Committee on Thick Film Coatings and Surfacings for Concrete, and are proposed as additions to the next revision of the SSPC ProtectiveCoatings Glossary.
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Tie-In: In an installation sequence, the joining of additional
material to material already placed.
4. Pre-Application Procedures
4.1 Condition Surveys: Accurate and thorough condition
surveys should be performed by experienced and qualified firms
or personnel prior to specification preparation. Surveys should
be carried out according to referenced standards, including
but not limited to ACI 201.1R-92 and ICRI Guideline 03732.
Appendix A provides background information about charac-
teristics of concrete designed for resinous floor coating ap-
plication.
4.2 General Concrete Substrate Requirements: Proper
design and placement of the underlying concrete are essential
to the proper performance of any resinous surfacing system.
Appendix A addresses critical issues that should be considered
in the composite system of concrete and its surfacing, but is
not all-inclusive. Detailed concrete and concrete substraterequirements are discussed at length by ACI 364.1R-94, ACI
201.2R-01, ACI 546R-96; ICRI Guidelines 03730, 03731 and
03732; and The Fundamentals of Cleaning and Coating Con-
crete, as well as a host of other standards and publications.
5. General Surface Preparation
5.1. Treatment for Alkali Silica Reaction: Sections of
surfaces with unacceptable levels of Alkali Silica Reaction (ASR)
should be treated either by application of a mitigating surface
treatment approved by the surfacing manufacturer or by removal
and replacement according to specifications or using methods
as described in ICRI 03730. See Appendices A.2.2.1 and B.2.1for discussion of ASR and remediation procedures.
5.2Moisture Vapor Transmission Rate: If the moisture
vapor transmission rate exceeds 3 lbs per 1,000 ft2in 24 hours
as tested in accordance with ASTM F 1869 or E 1907 or exceeds
the minimum moisture levels recommended by the surfacings
manufacturer, coatings or surfacings should not be applied until
moisture levels meet required limits. If the project schedule
must be expedited, moisture levels may be adequately reduced
by various commercial surface treatments. (See Appendices
A.2.2.2 and B.2.2 for discussion of MVT and its mitigation.)
5.3Following rehabilitative treatments, the surface should
be retested in accordance with ASTM F 1869 or ASTM E
1907.
5.4 The surface should be checked for the presence of
chlorides, sulfates, and other soluble salts in a manner accept-
able to the owner or surfacing manufacturer. See Appendix
B.2.3 for more details. Soluble salt samples used for testing
should be extracted and analyzed according to procedures
established in the procurement documents or per the coat-
ing manufacturers recommendations. If soluble salt removal
is required but no method for extraction and analysis of test
results is specified or stated by the owner, agreement between
contracting parties on acceptable methods of testing for soluble
salt contamination should be reached prior to starting the job,
in a manner acceptable to the surfacing manufacturer.
5.5 All surface imperfections should be repaired before
surfacing. Repair materials and methods should comply with
specifications and/or manufacturers instructions. Generally,
surface repairs are made with mortars of the same or similar
resin bases as the floor surfacing to be placed. For example,
epoxy mortars should be used for substrate repair over which an
epoxy surfacing is to be applied; urethane mortars where ure-
thane flooring will be applied; vinyl ester mortar where vinyl ester
flooring will be applied, etc. As an alternative, polymer modified
concrete can be used for repairs based upon manufacturers
recommendations. Appendices B.3 and B.5 provide information
on repair procedures, as does ICRI Guideline 03733.
5.6 The concrete surfaces to which repair material will be
applied should be sound and solid, free of dust, dirt, greases,
and oils. Appendix B.4 provides information on removal of oil
and grease.
5.7Surface Profile: Surfacings and coatings generally
form a bond through mechanical attachment during the curing
process. A profiled substrate surface will gain maximum adhe-
sion. ICRI Guideline 03732 provides comprehensive, informative
guideline tools that are useful in determining required profiling
methods. Plastic replicas of typical surfaces produced by these
methods are useful in correlating specified profile to that which
is produced or required in the field. Optimum profile is required
to produce proper adhesion and performance of coatings andsurfacings; too little or too much substrate profile may be
detrimental to performance of a specific overlay system. See
Appendices B.8 and B.9 as well as SSPC-SP 13/NACE No. 6
for additional details on surface preparation of concrete.
5.8 Masking and Protection:Surfaces adjoining or ad-
jacent to the area being finished that are not intended to be
coated or surfaced should be protected from trowel, power
trowel, roller spatter, overspray and other misplacement of
materials, as well as from dirt, dust or debris generated by the
application operation (see Appendix B.11.1).
6. Application of Thick Film Coatings andSurfacings
6.1 Pre-Application Procedures: The work area should be
checked to ensure environmental conditions for application are
within specifications, that the work area layout facilitates ease
of application, that traffic control procedures are in place, and
that adequate lighting is provided (see Appendix B.10.4).
6.2 Mixing: Most resins (unless mixed by an application
unit) and aggregate blends should be mixed in accordance with
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specifications and the surfacing manufacturers requirements.
See Appendix B 11.2 for more detail.
6.3 Priming:Most manufacturers floor coating and surfac-
ing systems require use of primers to enhance adhesion of the
system to the prepared substrate and to minimize outgassing,
the release of air from concrete as concrete temperature rises
(see Appendix B.11.3).
6.4 Examination for Contaminants:The surface should
be inspected for other contaminants which may have formed
during or following cure, such as dirt, dust and other forms
of debris, as well as for oils or other substances which may
have collected on the surface. Depending upon the facility or
operation, the ongoing processes may generate dust, dirt, or
oily mists that may collect on a cured surface. People may
walk over cured or uncured surfaces, especially after applica-
tors leave the project, tracking contaminants on the surface.
Detection and removal of contaminants prior to next applica-
tion is required for adhesion. Under certain conditions epoxy
primers or intermediate coats may develop amine blush, which
must be removed prior to application of subsequent coatings
or surfacings. Inspection for and removal of all contaminants
prior to any subsequent application of coatings or surfacings
is necessary for their proper adhesion. See Appendix B. 11.4
for more detail.
6.5 General Application Techniques:Application idiosyn-
crasies of specific coating and surfacing types are detailed in
Appendix B.12. Appendix B.10.5 describes some of the spe-
cialized application equipment used for application of surfacing
materials.
6.5 Recoat Time: The recommended recoat time for ap-
plication of the next coating or surfacing layer should be strictly
observed. Some systems require immediate application of the
next material to be installed directly into wet primer. Others vary
by time and temperature, and still others require the primer to
be cured. Specifications and manufacturers data sheets and
application instructions should be consulted for specific direc-
tion.
6.6 Application of Aggregate (if required):Slipresistanceis generally attained by adding specifically sized or graded
aggregates such as aluminum oxide, garnet, steel, silica or
polypropylene beads to the final finish. Thicker flooring systemsmay utilize other methods that will be described in the following
sections. The degree of slip-resistant texture is best chosen by
the user. The specifier and applicator are cautioned against
making final texture selection for the user. Both specifier and
applicator, however, can work together to provide submitted
samples of texture to the owner or user for final approval and
selection (see Appendix B.12.2).
7. Post Application Procedures
7.1 Cleanup: After application, the project area should
be cleaned to a broom-clean condition, or to the condition
required by the contract specification. All trash and construction
debris should be properly disposed off-site or in designated
disposal areas. All masking and protection should be removed
(see Appendix B.14.1).
7.2 Touch up: Any coating or surfacing irregularities
discovered after masking and protection have been removed
should be touched up according to repair procedures approved
by the owners representative (see Appendix B.14.2).
7.3 Tools, equipment, and materials: All equipment,
tools and unused materials should be removed from the site
(see Appendix B.14.3).
7.4 Protection: If required by specification or agreement,
the floor should be protected as specified or with appropriateprotection material such as plywood or composite board with
taped joints, laid over polyethylene sheets (see Appendix
B.14.5).
8. Inspection
8.1Qualified, full time inspection by the owners inspector
or a third-party inspector should be performed from job-start to
job-completion, especially during preparation and application
operations, to provide a systematic, efficient quality control pro-
cedure by which to assist the owner and contractor in meeting
specified and manufacturers requirements. Inspections and stop
points are best established prior to beginning the installation.Positive results gained by qualified, full time inspection cannot
be overemphasized, and is deserving of greater detail beyond
the scope of this document. For the purposes of this docu-
ment, inspection should be continuous, ensuring prerequisite
requirements of operations are carried out completely, tested
and results recorded according to specifications, manufacturers
requirements and as suggested by this technology update.
8.2 Before final cleanup, inspect the project for devia-
tions in specifications. Deficient work should be corrected in
accordance with repair procedures as approved by the owners
representative. The following is a list of qualities or properties that
are defined and agreed upon prior to installation and should be
inspected in the course of application and after completion
:
Uniform color
Gloss
Texture and degree of slip resistance
Straightness and neatness of termination lines
Planarity of floor
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Depressions or humps in sloping runs which could
affect liquid flow
Smooth transitions at floor and trench drains
Smooth finishes at cove radii, internal and external
corners
Smooth transitions at in-floor terminations
Smooth transitions at intersections of adjacent floor
surfaces
Full application and finished edges of sealants
Spatter of cured and uncured resinous materials on
surfaces not being coated
8.3 Final Inspection. After final clean up, and any prelimi-
nary deficiency remediation, reinspect according to procedures
described in this section.
9. Disclaimer
9.1This technology update is for information purposes only.
It is neither a standard nor a recommended practice. While everyprecaution is taken to ensure that all information furnished in
SSPC technology updates is as accurate, complete, and useful
as possible, SSPC cannot assume responsibility nor incur any
obligation resulting from the use of any materials, coatings, or
methods specified herein, or of the technology update itself.
9.2 This technology update does not attempt to address
problems concerning safety associated with its use. The user
of this specification, as well as the user of all products or prac-
tices described herein, is responsible for instituting appropriate
health and safety practices and for ensuring compliance with
all governmental regulations.
10. References
Farney, James A. and Kosmatka, Steven H. Diagnosis and
Control of Alkali-Aggregate Reaction in Concrete.
Skokie, IL, Portland Cement Association 1997: ISBN
0-89132-146-0.
The Fundamentals of Cleaning and Coating Concrete. Pitts-
burgh, PA, 2001: SSPC - The Society for Protective
Coatings. SSPC 01-10, ISBN 1-889060-61-5.
The Inspection of Coatings and Linings. Pittsburgh, PA,
2003: SSPC - The Society for Protective Coatings.
SSPC 03-14, ISBN 1-889060-75-5.
Appendix A: Background Information
A.1 General Concrete Substrate Requirements
Detailed concrete and concrete substrate requirements
are discussed at length in ACI 364.1R-94, ACI 201.2R-92,
ACI 546R-96; ICRI Guidelines 03730, 03731 and 03732; and
The Fundamentals of Cleaning and Coating Concrete, as well
as a host of other standards and publications. Although the
enormity of the subject matter could easily command several
sets of specific documents, the intent of this document and
this section is to provide the owner, specifier, manufacturer,
contractor, inspector and other interested parties with concise,
pertinent information and data as they generally relate to coat-
ings and surfacings applied over concrete floors. It is important
for the reader to understand that this document only addresses
critical, yet not all-inclusive, issues that should be considered
in the composite system of concrete and its surfacing.
Concrete is mainly a mixture of Portland cement, water,
and mineral aggregate, usually sand and gravel. Sometimes
additives are used such as fly ash and pozzolans. The mixture
cures and hardens by hydration. Water in the mix combines
chemically with the cement to bind the aggregate into the rigid
mass known as concrete. Although properly formulated and
cured concrete is strong and rigid, it can be attacked both
physically and chemically. Physical attack usually results in
cracking and spalling. Concrete is very strong in compression
but relatively weak in tension. It can and often does crack.
Concrete is also fairly porous and subject to osmotic and capil-
lary forces that absorb and release water. Absorbed water can
freeze within the concrete and cause spalling and cracking.
Strength-gain, wear-resistance, and shrinkage properties
of every concrete mix design are affected by the water-to-
cementitious (w/c) ratio, normally expressed as the weight
(pounds) of mixing water per weight (pounds) of cement.
Concrete with a lower water-cement ratio gains more strength
than concrete with a greater one, but such low ratios may be
difficult to place and consolidate properly because of the stiff-
ness of the mix. Chemical admixtures (water reducers) are
often used to increase workability of the concrete while keeping
the water-cement ratio low. High water-cement ratios increase
shrinkage cracking and reduce surface wear resistance andcompressive strength.
Approximately 0.19 lb of water for each 1 lb of cement is
required for complete cement hydration. Roughly twice that
ratio, or 0.38 lb of water per each 1 lb of cement, is required
for mixing, because additional water is absorbed on gel pore
surfaces and the cement particles must all be wetted. More
water may be added to enhance workability when placing con-
crete, but any amount in excess of 0.38 lb per lb of cement is
not required for the hydration process and may eventually leave
the concrete via evaporation or as bleed water. Such excess
water increases shrinkage and contributes to the formation of
cracks and continuous capillaries in the hardened concrete
paste. These capillaries become channels for moisture move-ment and for intrusive and harmful chemical solutions after the
cured concrete is placed in service. Wet curing will minimize
incidence of these capillary channels.
A.1.1 Designing floors for resinous floor systems: While
concrete slabs should be placed in accordance with standard ACI
practices, it is equally important that the concrete be designed
to accommodate the intended end use. A water-cured, light
steel troweled finish is most suitable for subsequent application
of resinous systems. Any placement method, however, that
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maximizes surface strength is acceptable. Minimal finishing
normally produces the strongest surface.
Wet-cured concrete (ACI 308-92, Chapter 2), by use of
burlap and waterproof cover, is preferred over use of curing
compounds. Although excellent curing compounds are avail-
able, proper wet curing facilitates hydration without potential for
chemical interference of the curing compound with subsequent
resinous system application.
New concrete (Type 1 Portland cement) is designed to
develop about 80% of its design strength in 7 days and nearly
all of its overall strength in 28 days. Excess residual or free
water not used in the hydration process of cement will continue
to migrate out of the concrete until it reaches equilibrium with
its environment. There is a potential problem in the placement
of resinous systems over new concrete even after 28 days if
excess water is still present, if the excess water is continuing to
move from the concrete to the environment above the slab. It is
the movement of moisture vapor within the slabnot the total
quantity of moisture within the slabthat creates subsequent
problems with non-permeable floor surfacings.
An effective concrete substrate must be low in permeability
and high in density. The general mix design shown in Table A.1
is an example of a mixture that will yield a suitable substrate.
Tensile bond strength of a concrete substrate is important
in concrete design. Tensile strength of concrete is approximately
10% of its compressive strength.Most resinous surfacings
manufacturers prefer minimum tensile bond strength to be 350
psi as measured per ASTM D 4541.
A.2 Surface Preparation Considerations for Concrete
Substrates
A.2.1 Chemical Attack: Chemical attack can occurbecause concrete is alkaline and chemically reactive. It can
be attacked by mineral acids; some alkalis; numerous salt so-
lutions; and organic acids such as fermenting liquids, sugars,
and animal oils. Corrosive solutions penetrating to the steel
reinforcing may be particularly destructive because the large
displacement of corrosion products of steel can cause cracking
and spalling of concrete.
A.2.2 Alkali Silica Reaction (ASR) and Moisture Vapor
Transmission (MVT):ASR and MVT are major causes for failure
of coatings and surfacings applied to on-grade or below-grade
concrete. Both ASR and MVT are discussed together in this
subsection, as continuing research seems to bear out a homo-geneous relationship between the two phenomena. Evolving
data suggests moisture vapor to be the transmission force that
drives greater deleterious effects of ASR toward the concrete
surface and the bond line of resinous surfacings, resulting in
high potential for adhesion loss.
A.2.2.1 Alkali-Silica reaction (ASR)occurs in concrete
when soluble alkali ions such as sodium and potassium react
with chemically active forms of silica (usually present in the
sand or gravel aggregate). The reaction produces an expansive
gel, which absorbs a significant quantity of water. Expansion
of the amorphous silica gel creates internal pressures within
the concrete leading to paste fractures and deterioration of the
concrete.
ASR is manifested by cracking followed by spalling,
strength loss, and disintegration of the concrete matrix, which
sometimes causes pop outs, fragments of concrete that break
away leaving a shallow, conical depression.
When the amount of alkali is greater than the amount of
reactive siliceous aggregates the alkali silica gel may absorb
water and swell, causing expansion soon after curing. This is
frequently manifested after one or more years.
A.2.2.2 Moisture Vapor Transmission (MVT): Water or
liquid moves through concrete through small pores, or capillar-
ies, in the form of vapor, always from an environment of high
vapor pressure to low vapor pressure. Vapor pressure combines
the effects of temperature and humidity. In general, moisture
migrates from warm, humid conditions to cool dry conditions.
If the environment below a concrete slab is continuously
wet, capillary action will pull liquid from below the slab into the
slab, but moisture most frequently moves in concrete as a vapor
driven by the differential in vapor pressure.
Providing drainage under the concrete slab helps to reduce
the source of water below it. Use of vapor barriers is required
to eliminate moisture sources from below the slab. The vapor
barrier should meet the requirements of ASTM E 1745, with a
permeability rating of 0.30 or less. Placement of this moisture
barrier must be continuous and in compliance with ACI 504.
ACI 302 recommends a two-inch layer of granular self-draining
compactable fill above the vapor barrier. If this recommended
practice is followed, extraordinary measures must be taken to
keep this fill dry. If water is allowed to be captured within thislayer, it will serve as a water reservoir under the slab. In most
cases, it is more advantageous to pour the concrete directly
onto the moisture vapor barrier, and use moisture curing tech-
niques to prevent drying shrinkage cracking. As vapor is driven
through the concrete, soluble alkali ions are transmitted with it
and collect at the surface. When moisture cycles back into the
slab, concentrating the ionic solution, crystals can form which
can create enough force to disbond a resinous surfacing. If
undetected, the combined phenomena of MVT and ASR will
generally result in bond failure when concrete is used as a
substrate over which resinous surfacings are applied.
Determination of the extent of ASR deterioration and sub-
sequent concrete substrate treatment, whether removal andreplacement or in-situ rehabilitation by specific rehabilitative
treatments, is best determined by qualified firms or personnel
during the specification preparation process.
A.2.3 Carbonation: Although naturally occurring in all
atmospherically exposed concrete, the fine surface crazing
and softening of concrete upper surfaces particularly mani-
fests itself when the surface is exposed to increased levels of
airborne carbon dioxide during the hardening stage. Exhaust
from direct-fired heaters commonly used during cold weather
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increases the carbon dioxide levels, and is a leading, though
not the only, cause of carbonation.
Generally, carbonated concrete surfaces are soft or pow-
dery, with insufficient tensile strength to maintain substrate
bonding properties required for surfacing adhesion. Standard
adhesion testing methods according to ASTM D 4541 can
be used to determine concrete surface strength required by
surfacing manufacturers and/or specifications (see Appendix
B.1). A concise discussion of carbonation can be found in the
chapter entitled "Condition Assessment" in Fundamentals of
Cleaning and Coating Concrete).
A.3 Amine Blush
Following the cure of primers and other applied layers over
which additional coatings or surfacings will be installed, the
surfaces should be inspected for the presence of amine blush
and other contaminants that could prevent or inhibit adhesion
and contribute to intercoat delamination.
Amine blush manifests itself as an oily, greasy, waxlike
residue over the surface of a cured coating or surfacing, caused
by rapid solvent evaporation or the reaction of an amine com-
ponent, generally in the presence of moisture or high humidity
and/or in low temperatures. Specifically, an amine co-reactant
in a coating or surfacing reacts with carbon dioxide and water
to form an amine carbonate, which can, and usually does,
adversely affect adhesion of subsequent coating or surfacing
applications. Recognition and removal of amine blush is critical
for successful installations.
Manufacturers do not uniformly indicate on system data
sheets or application instructions product susceptibility to amine
blush or precautions to be taken if their specific products are
susceptible to amine blush. Product usersowners, specifiers,contractors and inspectorsshould contact the manufacturers
Technical Service Department directly for clarification if precau-
tions about amine blush are not published.
Conditions of high humidity or moisture or low or declining
temperatures during cure, and especially the combination of
high humidity or moisture and low or declining temperatures
during cure, present high potential for blush formation.
In colder climates, isolated areas away from heat, espe-
cially near exterior walls may develop amine blush, while other
areas may not. Close inspection of the entire area is recom-
mended, paying particular heed to susceptible isolated areas.
Air-conditioned areas may also present environments suitable
for formation of amine blush.
Advanced stages of amine blush formation are easier
to detect than less advanced formations. At this writing, no
recognized standard or test method exists for detection of
amine blush, limiting inspection to subjective powers of visual
observation and touch. In its most advanced stage of formation,
amine blush is evidenced by a milky-white opalescence on a
surface, feeling very oily or greasy to a point where the surface
is slippery. Initial appearance might indicate to the observer
that the coating or surfacing did not cure. Less advanced
formation stages may not exhibit a milky-white opalescence,
but may present only a slight oily or greasy residue, difficult to
feel. This stage of formation is the one that creates the most
difficult problem, as subjective discovery or recognition of the
phenomenon may be overlooked or missed.
Amine blush can be removed by detergent washing.
Solvent washing is not recommended as residues may leave
chloride salts and other bond-inhibiting contaminants on the
surface. Blush is best removed by use of a floor scrubber utiliz-
ing detergent and warm water, followed by thoroughly rinsing
the scrubbed surface. Allow treated surface to dry completely,
and then reinspect the surface. Rewash, rinse and allow drying
if blush is detected. Then reinspect. Usually amine blushing is
easily removed with a single wash and rinse.
During winter months in colder climates, or at any time or
location where conditions may be likely to produce amine blush,
it may be appropriate to treat the surface according to Appendix
B.11.4, as if amine blushing is present, but undetected.
Appendix B: Detailed Preparation andApplication Procedures
B.1 Condition Assessment of Existing Substrate
The substrate receiving the surfacing should be examined
carefully prior to specification preparation. Accurate and thor-
ough condition surveys conducted by experienced and quali-
TABLE A.1
EXAMPLE OF GENERAL MIX DESIGN
Cementitious Content (minimum) 517 lbs/cubic yard
Water-Cement Ratio (by weight) 0.40-0.45
Maximum Coarse Aggregate Size 1-1/2 inches
Air content 4-6%
Slump (without high range water reducers) < 3 inches
Slump (with high range water reducers) 6-9 inches
Compressive Strength (28 days) 5,000 psig
Permeability low
Cement options
Water
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fied professional firms or personnel are recommended prior
to specification preparation. Surveys should be carried out as
described in referenced standards, including but not limited to
ACI 201.1R-92 and ICRI Guideline 03732.
Floors should be examined for grease and oil deposits.
Inspection by core testing is recommended in areas where
oils or greases have extensively contaminated concrete for
long periods. Cores that exhibit contamination present to a
depth of 1 in (25 mm) or greater usually require removal of the
contaminated concrete surface, rather than remediation tech-
niques, to achieve a surface condition suitable for adhesion of
coatings or surfacings. Determination of the best strategy for
oil and grease removals should be developed during specifi-
cation development, as described in Section B.4. Removal or
remediation techniques may be time consuming. Developing
a plan for proper treatment in the specification helps to ensure
correct conditioning and timely execution. Investigate the
facility operation to determine potential presence of unusual
contaminants. Existing sealers, coatings or surfacings must
be removed or treated in accordance with specifications and
surfacing manufacturers requirements.
A non-laboratory field inspection of the substrate should
include:
Verification of the dimensions of the substrate.
Verification that the planarity and slope meet require-
ments and/or specifications.
Verification that the concrete surface strength meets
the surfacing manufacturers requirements. Generally,
minimum surface strength of 200 psi as measured
as described in ASTM D 4541, is required for floor
surfacing adhesion. A strategy should be developed
for rehabilitation or removal (Section B.3) of areas
of inadequate surface strength in accordance withmanufacturer requirements.
Determination of the presence of chlorides, sulfates
and other soluble salts in accordance with the pro-
curement documents or the surfacing manufacturers
guidelines. Contaminating salts are frequently pres-
ent in plants and other facilities where chemicals and
solvents are used. Contaminants should be removed
in accordance with manufacturers recommendations
or as described in Sections B.2.
Determination of the presence of existing sealers, coat-
ings or surfacings. The treatment strategy should be
in accordance with specifications and manufacturers
requirements. Determination of the moisture vapor transmission rate
in accordance with ASTM F 1869 or E 1907.
Determination of the presence of Alkali Aggregate
Reaction (see Section B.2.1).
Both static and moving cracks should be identified and
treated in accordance with the surfacing system manufacturers
requirements or as described in Section B.5. Spalls, pop-outs,
aggregated surfaces and other imperfections should be noted
and treatment strategies developed as described in the surfacing
manufacturers requirements or as described in Section B.3.
For at least two weeks prior to application, environmental condi-
tions should be representative of normal operating conditions
at the facility in order to allow the concrete substrate to reach
equilibrium.
Any irregularities which do not meet the specifications
should be brought immediately to the attention of the project
governing authority
B.2 Surface Treatments
B.2.1 ASR Mitigation:Alkali Aggregate Reaction (AAR),
including ASR (Alkali Silica Reaction) is a major cause of the
failure of coatings and surfacing over concrete, but it is not
easily detected in the field. It is best determined by recognized
testing agencies equipped to perform petrographic analysis. If
levels of ASR have been discovered and the condition of the
substrate has been determined to be treatable by removal and
replacement of specified sections of concrete substrate, those
sections should be removed and replaced according to contract
specifications or using the methods described below. If ASR
mitigation has been determined to be treatable by mitigating
surface treatment techniques approved by the surfacing manu-
facturer, those procedures should be carried out according
to the contract specification or the surfacing manufacturers
instructions.
B.2.2 MVT Mitigation:Moisture vapor transmission, as
defined in Appendix A, must be controlled in order to prevent
subsequent bond problems with an installed impermeable
coating or flooring system. The moisture vapor transmission
rate should be determined in accordance with ASTM F 1869
or E 1907. If the project schedule must be expedited, moisturelevels may be adequately reduced by various commercial
surface treatments, which should be used in accordance with
specifications or as approved by the owner and the surfacings
manufacturer. The surface should be retested in accordance
with ASTM F 1869 or ASTM E 1907 following rehabilitative
treatments.
If the moisture vapor transmission rate exceeds 3 lbs/1,000
ft2/24 hours (15Kg/100m2/24 hours) as tested in accordance
with ASTM F 1869 or ASTM E 1907, or exceeds the minimum
moisture levels recommended by the surfacings manufacturer,
do not apply coatings or surfacings until moisture levels meet
required limits.
B.2.3 Soluble Salt Mitigation
B.2.3.1 Removal: If soluble salts, such as chlorides,
sulfates and nitrates, are found or suspected to be present,
they should be removed or the concrete treated prior to instal-
lation of coatings or surfacings. Such removal is generally
accomplished by high pressure water cleaning as described
in SSPC-SP 12/NACE No. 5. Normally, High-Pressure Water
Cleaning (HP-WC) performed at pressures from 34 to 70 MPa
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(5,000 - 10,000 psi) is adequate for salt removal. Commercial
decontaminating treatments are available which reduce amounts
of required water consumption and pressure.
B.2.3.2Testing: Contaminating salts are frequently pres-
ent under existing conditions in plants and other facilities where
chemicals and solvents are used. Current industry standards
do not specifically address extraction and analysis of soluble
salts in concrete, however data is evolving. Soluble salts and
other similar contaminants should be removed according to
specification or as required by the surfacing manufacturer.
B.3 Repair of Surface Imperfections
Dings, holes and surface imperfections (other than cracks)
that are less than 1/2 inch in depth and 2 inches in diameter
should be filled with the same or similar resin as the coating or
surfacing, compounded into a mortar or gel, or fillers recom-
mended by the surfacing manufacturer.
Holes, spalls and other surface imperfections that are
greater than 1/2 inch in depth and 2 inches in diameter, where
steel reinforcing IS NOT exposed, should be prepared so that
the repair area is squared up and shouldered. Terminations of
all repairs should be extended to a vertical abutment. Flash-
patched edges, or edges terminated at a skim coat level on
top of the concrete substrate, are not recommended. Sound
out the area surrounding the spall or hole by tapping with a
hammer on the surrounding concrete in all directions extending
from the repair area, listening for hollow sounds. The limits of
hollow sounds around the perimeter of repair area indicate the
limits of unsound concrete substrate. The perimeter area of
the unsound concrete should be marked with chalk.
The repair area should be marked by chalking out a rect-angle or square perimeter that includes the entire unsound
area. Refer to layout as illustrated in ICRI Guideline 03730,
Edge and Surface Conditioning of Concrete, Item 9. The
marked perimeter should be sawcut to a minimum depth of 5/8
in. (12 mm) or to a depth recommended by the repair product
manufacturer. Edge shoulders should be perpendicular to the
substrate surface, as illustrated in ICRI Guideline 03730, Item
8. The repair area, including edges, should be vacuum cleaned
and free of oils and greases. The repair material to be used
should be compatible with the surfacing manufacturers floor-
ing system. Repair methods should comply with specifications
and/or the manufacturers instructions.
Holes, spalls and other surface imperfections that aregreater than 1/2 inch in depth and 2 inches in diameter, and
where steel reinforcing IS exposed, should be repaired in ac-
cordance with ICRI Guideline 03730. Any unsound, disbonded
concrete above the reinforcing steel should be removed. The
extent of the unsound, disbonded concrete may be determined
by sounding methods described above and by evaluating the
soundness of the concrete during removal.
All exposed corroded steel reinforcing bars should be
undercut if exposed reinforcing steel is found to be rusted or
otherwise corroded after initial removals are made. A mini-
mum 3/4-inch (19 mm) clearance between exposed bars and
surrounding concrete, or 1/4 inch (6 mm) larger than the larg-
est aggregate, whichever is greater, should be maintained.
Concrete removals should extend along the bars to locations
where the bar is free of bond-inhibiting corrosion and is well
bonded to the surrounding concrete. If corroded bars have lost
significant cross-section, and this condition is not addressed in
the specifications, a structural engineer should be consulted
for further direction. The structural engineer may recommend
full bar replacement or the addition of a supplemental bar over
the affected section.
If non-corroded reinforcing steel is exposed during the
undercutting process, care should be taken not to damage the
bars bond to the surrounding concrete. If the bond between
the bar and the concrete is broken, undercutting of the bar
should be required. Any reinforcement that is loose should
be secured in place by tying to other secured bars or by other
approved methods. All heavy corrosion and scale should be
removed from the bar as necessary to promote maximum bond
of replacement material, preferably by blasting with oil-free
abrasive. Tightly bonded light rust buildup on the surface is
not usually detrimental to the bond unless a protective coating
is being applied to the bar surface. If a protective coating is to
be used, surface preparation of the bar should comply with the
manufacturers instructions.
Supplemental replacement bars used to correct eroded
bars may be mechanically spliced to old bars, or supplemen-
tal bars may be placed parallel to and approximately 3/4" (19
mm) from existing bars. Lap lengths should be determined in
accordance with ACI 318.
Contractors and manufacturers should exercise particular
caution regarding repair or rehabilitation of reinforcing steel.Load design is outside the domain of those not licensed or
qualified to fully analyze structural requirements.
The repair material selected should be compatible with the
surfacing manufacturers flooring system and should be installed
in strict accordance with specifications and repair material
manufacturers requirements. Generally, surface repairs are
made with mortars of the same or similar resin bases as the
floor surfacing to be placed above it. The concrete surfaces
surrounding areas to which repair material will be applied should
be sound and solid, free of dust, dirt, greases, and oils.
The repair area, including shoulders, must be vacuum-
cleaned, free of dust, dirt, greases, oils, and any other contami-
nants that may inhibit bond. The edges of deficient areas thatrequire planarity and sloping correction prior to application of
surfacings should be keyed-in to terminate at square shoulders
or edges without flash patching. After determining the substrate
area to be corrected, chalk-lines should be snapped to outline
the perimeter. The substrate should be sawcut to a depth of 1/4
inch (6 mm) or twice the thickness of the surfacing material to
be installed, whichever is greater. If surfacing material is less
than 1/8 inch (3 mm) thick, the kerf (the width of the saw blade)
must be at least 1/8 inch (3 mm) in width. If surfacing material
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is 1/8 inch (3 mm) or greater, another sawcut to a depth of 1/8
inch (3 mm) inside the perimeter should be made. The distance
between the outside and inside sawcuts should be:
3 inches (76 mm) for surfacing material thickness up
to 3/16 inches (5 mm);
4 inches (101 mm) for surfacing material thickness
up to 3/8 inches (10 mm);
For surfacing thickness greater than 5/8 inch (13 mm), the
distance between the two sawcuts should be an additional
1 inch (25 mm) for each 1/8 inch (3 mm) thickness over 5/8
inch (13 mm).
After the outside and inside sawcuts are made, the key is
created by chipping out concrete between them, making a slop-
ing transition that increases in depth from the inside to outside
sawcuts. The profile within the substrate correction area should
be created as described in ICRI Guideline 03732, and as later
described in this document. The repair material selected should
be compatible with the surfacing manufacturers flooring system
and should be installed in strict accordance with specifications
and repair material manufacturers requirements.
B.4 Removal of Oil and Grease
Oil and grease should be removed from concrete sub-
strates prior to subsequent surface profiling and application of
any other coating or surfacing materials. If concrete removal
is specified or required, remove concrete according to contract
specifications or Section B.3.
Water soluble or detergent-emulsifiable contaminants
should be removed by scrubbing with a detergent solution
as described in ICRI Guideline No. 03732. Following the ap-
plication of suitable chemical detergent solution, the surface
should be scrubbed with a stiff-bristled broom, brush, or scrub-bing machine. Used solution should be collected and properly
disposed. The process should be repeated as necessary to
achieve acceptable results.
Oils and greases that are not water soluble or detergent-
emulsifiable may be removed by use of steam. Steam should
be applied over the affected area to allow oil or grease to rise
to the surface. Residue should be removed and the surface
should be rinsed clean. The process should be repeated until
acceptable results are achieved.
Some surfacing manufacturers offer oil-tolerant primers,
generally applied after mitigating techniques described above.
Job specifications or surfacing manufacturers instructions
should be followed carefully when using these primers.
B.5 Repair of Cracks
Cracks should be pretreated prior to application of any
coating or surfacing, unless otherwise directed by specification
or surfacing manufacturer. Generally, surfacing thicknesses
less than 3/16 inch (5 mm) will mirror substrate cracking, even
if the cracking is non-moving.
Non-structural, non-moving cracks should be routed
open with a saw, grinder or concrete routing apparatus
to a minimum depth of 1/2 inch (12 mm).
Cracks less than 1/8 inch (3 mm) in width should be
opened to at least 1/8 inch (3 mm).
Cracks greater than 1/8 inch (3 mm) but less than 1/4
inch (6 mm) in width should be opened to at least 1/4
inch (6 mm) in width.
Cracks 1/4 inch (6 mm) or greater should be cut on
both sides of the crack, opening the crack wider than
the existing width.
All cracks should be vacuum cleaned to remove dust, dirt
and debris. To repair the concrete and return the substrate to
a monolithic surface, prepared cracks should be filled with the
same or similar resin as the coating or surfacing, compounded
into a mortar or gel or crack filler as recommended by the
surfacing manufacturer.
Structural cracking, especially that found in suspended con-
crete around structural members and large moving machinery,
should be analyzed by qualified engineering professionals to
determine the relationship of cracking to the overall construc-
tion integrity.
Structural cracks may be moving or non-moving, with
stabilization and treatment methods determined by engineering
professionals. Non-moving cracks are generally stabilized by
several methods, including providing additional support and
epoxy injection. If future movement of a crack cannot be ruled
out it should be treated as a moving crack.
Moving cracks in stabilized concrete are generally treated
as functional joints (see Section B.6). The effects of movement
are controlled by the use of flexible sealant systems, compres-
sion seals, and other treatments over which hard coatings and
surfacings are usually not applied. Hard, inflexible coatings andsurfacings will not absorb movement and will reflect substrate
cracking, requiring functional joints or cracks acting as func-
tional joints to be incorporated separately as part of the finished
coating or surfacing system. They should not be overcoated.
Irregularly-shaped moving cracks are usually straightened by
completely filling the crack with an adhesive resin, usually epoxy,
then making a straight sawcut between the two endpoints of
the crack.
Cutting a joint to a minimum depth of 1 inch (25 mm) by
1/4 inch (6 mm) wide, with the bottom of the sawcut ending
above the steel reinforcing, will provide a new controlled crack
plane.
Topical treatments and filling of cracks by the use of flexiblemembrane systems helps to absorb or cushion movement and
mitigate substrate crack reflection through an overlaid surfac-
ing. Any topical membrane treatment should be used in strict
accordance with specifications and surfacing manufacturers
instructions. Certain membrane systems may require placement
of tape or wax bond breaker material over the crack. Usually
a 1-inch (25 mm) wide bond breaker material is centered over
the crack, and a 4- to 6-inch (101 to 152 mm) membrane,
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sometimes reinforced with fiberglass, is applied over the bond
breaker. Other membrane systems may not require the use of
bond breakers, but may require that the crack be pre-filled with
a flexible product prior to application of the membrane.
Additional information on concrete cracking may be found
in SSPC TU 2/NACE 6G197, The Fundamentals of Cleaning
and Coating Concrete, and ACI 224-1 (latest revision).
B.6 Preparation of Joints
Joints comprise an integral part of concrete structural
design, particularly for floors, providing planned, systematic
details to accommodate concrete placement. They also allow
for contraction during curing, expansion and contraction during
temperature variations, differential settlement and crack con-
trol. It is important to be able to identify the functions of joints
encountered in coatings and surfacings work, and to treat each
joint in a manner that retains its full functionality. ACI 116R de-
fines five functional joints. Unless otherwise specified, without
other special treatments, coatings and surfacings should not
be placed over functional joints. Movement in functional joints
generally exceeds elongation at break properties of coatings
and surfacings, resulting in cracking of finished work above or
in proximity of the covered joint.
Existing joints should be prepared by removing existing
fillers, sealants or other materials prior to coating or surfacing
application. Following removal of joint materials, both sides of
the joint should be sawcut to create clean, bondable surfaces.
The surface should be vacuum cleaned after sawcutting.
Benchmarks may be created by driving nails or other devices
into the center of prepared joints, along straight runs, to allow
for later sawcutting and sealing following completion of fin-
ished coatings and surfacings. If the contract specification ormanufacturers recommendations require joints to be covered
with coatings or surfacings without other special treatments,
the appropriate sealant should be installed as described in the
contract specification or the surfacing manufacturers instruc-
tions. SSPC TU-2/NACE 6G197 offers substantial guidance
on joint designs, and should be consulted in detail, especially
for special joint treatments.
Where joint width and depth are greater than 1/4 x 1/4 inch
(6 x 6 mm), the depth of sealant should be one-half (1/2) the
width of the joint, generally not exceeding a minimum width of
1/4 inch (6 mm) and a maximum depth of 1/2 inch (13 mm).
Joint fillers, such as dry sand, or commercially available backer
materials, such as closed cell foam backer rods, can be usedto control sealant depth. Sealant should adhere to both sides
of the joint, but not to the bottom, as three-point bonding gen-
erally results in sealant failure. Bond breaking material, such
as a polyethylene strip or plastic- faced electrical tape, should
be placed over other backer materials to prevent adhesion.
Masking tape should be placed along both sides of the joint to
maintain neat, straight lines after the sealant is installed. The
amount of sealant installed should ensure that the joint is full
and flush with adjacent edges. Masking tape should be removed
prior to joint cure.
B.7 Coved Base Preparation
Integral coved base is that part of the finished flooring system
which terminates at floor edges by turning up abutments, such
as walls, equipment pads and other vertical surfaces, usually
from 4 - 8 inches in height (102 - 203 mm). It can vary from
a simple 1 inch (25 mm) spoon-cove to a wainscot applica-
tion covering the lower part or all of a wall. Vertical substrates
to which coved base may be applied may be constructed of
concrete, cement masonry units, glazed masonry units, brick,
wood or drywall. Care must be exercised to ensure that the
structure of vertical substrate is sound, solid, and stable. The
surface condition of a vertical substrate, especially drywall or
wood, should be inspected for soundness and compatibility
with the materials to be applied. Deteriorated drywall or wood
substrate sections may require removal and replacement with
more compatible substrate materials such as cement board.
Base design must be clear and understood to determine extent
of proper preparation and termination techniques. Some fac-
tors that determine preparation methods include, but are not
necessarily limited to:
Height of the base.
Existence of joints at or near wall-floor intersection.
Use of metal or plastic termination strip at top of
base.
Use of reglet (sawcut) as top termination.
Use of bullnose (rounded) top termination. Use of feathered top termination. Use of spoon-cove (radius) only. Use of splay or chamfered base.
Unless otherwise specified, the top of the coved base should be
parallel to the elevation of the finished floor, especially where
the floors are pitched or sloped, or the finished system mayhave an irregular appearance.
If the base is to be applied to finished wall surfaces, care-
ful masking and protection will be required during preparation
operations to minimize damage and staining. The use of duct
tape or other strongly adhesive tape may remove finished wall
surfaces. Tape such as 3M Long-mask, which are designed
to be removed with minimum surface pull-off, may result in
minimal damage. The planarity of the base substrate should
be repaired and patched with appropriate resinous or polymer-
cementitious materials as specified or as described in surfacing
manufacturers instructions. The substrate should be prepared
as discussed in Sections B.3 through B.6. Surfacings other than
troweled mortar systems may require the coved base to beformed from resinous or polymer-cementitious mortar applied
by trowel and then coated, tying-in the specified system at the
termination of the cove or splay. When this method is used,
metal or plastic termination strips placed at the toe of the cove
often result in better base-floor transitions. The top of the base
should be finished in straight, neat lines.
Joints at wall-floor intersections may require the use of
sealant to form the cove or splay to prevent cracking. Depend-
ing upon anticipated movement, other methods may be used,
such as forming the cove with sealant, applying a bond breaker
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over the sealant, then applying resin-impregnated fiberglass
from the top of the base to approximately 1 to 2 inches (102 to
203 mm) beyond the cove onto the floor.
B.8 Establishing Surface Profile
Surfacings and coatings require a profiled substrate surface
to gain maximum adhesion. ICRI Guideline 03732 provides
comprehensive, informative guidelines and tools that are use-
ful in determining required profiling methods. Plastic replicas
of typical surfaces produced by these methods are useful in
correlating specified profile to that which is produced or required
in the field.
After substrate surfaces have been rehabilitated to a sound
condition as described in preceding sections of this document,
the surface should be profiled to meet the specification or the
surfacing manufacturer's requirements for proper adhesion and
performance of coatings and surfacings. A substrate profile that
is either too low or too high may be detrimental to performance
of a specific overlay system.
B.8.1 Acid Etching:Acid etching is a practice used to
remove weak surface laitance and some foreign materials and
to produce a surface profile between 1 to 5 mils (25 to 125
m), as illustrated by ICRI Replicas CSP 1 to 3. Generally,
the profile produced by acid etching is suitable for sealers and
coatings with thicknesses up to 10 mils, which are outside the
scope of this technology update. However, acid etching may
be specified for use in special circumstances. ICRI Guideline
03732 and ASTM D 4260 describe acid etching techniques.
Acid etching is a preparation technique used with diminish-
ing regularity. Other profiling methods are generally preferred
and are more effective. Etching solutions are highly corrosive,and environmental considerations may require full contain-
ment and recovery of spent acid and rinsewater. Because the
etching process saturates the substrate, the substrate must be
allowed to dry prior to the application of most coatings, which
may impede installation schedules.
Acid etching is inappropriate if the concrete substrate
surface is sealed with sealers or coatings. In this case, other
profiling methods should be used. Oil, grease, and other pen-
etrating contaminants should be removed prior to etching. Pro-
truding surface irregularities should be removed by mechanical
means. The substrate surface should be pre-wet with water prior
to etching, with any freestanding water removed. The etching
solution (e.g., phosphoric or citric acid) should be preparedaccording to contract specifications and manufacturers instruc-
tions. Hydrochloric and muriatic acids (diluted hydrochloric or
sulfuric acid) leave soluble salts in the substrate and should
not be used where chlorides cannot be tolerated.
The etching solution should be applied uniformly over
the wet surface by use of polyethylene sprinkling cans or low-
pressure sprayers at the rate of 90 to 100 ft2(8 to 9 m2) per
gallon. The applied acid solution is agitated with a stiff bristle
broom or power brush for five to ten minutes and the surface is
not permitted to dry. When etching solution bubbling begins to
subside, surfaces should be flushed to remove reaction products
and inspected for uniform roughening and removal of laitance.
To obtain the required surface condition, several applications
of acid may be required. Any residue should be vacuumed
away and the surface should then be scrubbed with an alkaline
detergent. This process should be repeated until etching debris
is completely removed. The surface should then be rinsed with
clean, potable water, scrubbed and vacuumed dry. Rinse water
should be tested as described in ASTM D 4262. At least two pH
readings for each 500 ft2(46 m2) or portion thereof should be
taken at randomly selected locations following the final rinse but
before all the rinse water has drained off the surface. The pH
readings following the final rinse should not be more than 1.0
pH lower or 2.0 points higher than the pH of the water before
rinsing begins, unless otherwise specified.
B.8.2 Grinding:Grinding is generally used on concrete
substrates to reduce or smooth surface irregularities and to
remove mineral deposits and previously applied thin film rigid
coatings, usually less of than 6 mils (150 m) thickness. Grind-ing does not usually produce an acceptable profile over which
to apply coatings and surfacings; other methods, usually shot
blasting or scarifying, are normally used subsequent to grind-
ing treatments. Grinding may be accomplished by wet grinding
or dry grinding using portable equipment ranging from small
hand-held grinders to walk-behind units with multiple discs. Wet
grinding minimizes or eliminates airborne dust, but produces a
slurry residue. Slurry and rinse water should be collected and
properly disposed. Dry grinding produces fine airborne dust,
which may be controlled by use of dust control attachments.
B.8.3 Abrasive Grit Blasting:Concrete floors are seldom
cleaned by abrasive blasting because of the amount of dustgenerated in interior workspaces. While most often impractical
for concrete floor substrate profiling, abrasive blasting does
provide the capability to produce profiles ranging between ICRI
Replicas CSP 2 to 4, and may also produce profiles ranging
from 1 to 30 mils (25 to 750 m). Blast curtains and any other
containment media should be erected and in place to protect
people, property and the environment during blasting opera-
tions. The selected blast media should be of a type approved
by all environmental regulatory agencies. (Silica is a prohibited
abrasive blast medium in many areas of the US.) The blast media
should be clean and free of contaminants according to contract
specifications, SSPC-AB 1, or SSPC-AB 2. The size and type
of blast media should be appropriate to produce the desired
profile. Blast personnel should be trained and qualified to safely
use abrasive blast equipment and should be fully cognizant of
related environmental issues. All equipment should be properly
sized and filtered to produce an efficient blast media stream,
free of oil and moisture, complying with all safety regulations
and requirements. The final prepared surface should be free
of dust, dirt, debris and any bond-inhibiting contaminants.
B.8.4 Steel Shot Blasting: Steel shot blasting, generally
referred to as shot blasting, is the profiling preparation method
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most often recommended by coatings and surfacings manu-
facturers. Steel shot is centrifugally propelled to the substrate
surface at a high velocity within a closed blast chamber that
recovers and separates dust and reusable shot. The operation,
when using properly maintained equipment, generally produces
a minimum amount of dust, and is capable of producing profiles
ranging between ICRI Replicas CSP 3 and 8. Shot blasting
cleans and profiles concrete surfaces by removing dirt, laitance,
curing compounds, sealers and other superficial contaminants.
Prior to shot blasting, grease and oil that has penetrated the
substrate surface should be removed. Heavy dirt, foreign mat-
ter, and other debris, such as bolts, screws and other metallic
objects that could damage the shot blast equipment, should
also be removed. Shot blast equipment is available in a range
of sizes to provide ready access to most surfaces. Depending
upon the equipment used, edges and corners may be detailed
to within 1/4 inch (6 mm) of vertical surfaces. The depth of
removal is controlled by shot size, machine setup, and rate of
travel. As the depth of cut increases, profile will be increasingly
dominated by the size and shape of coarse aggregate in the
concrete. Generally, the maximum efficient depth of removal
in a single pass is 1/8 inch (3 mm). Shot between S-230 and
S-390 mesh is used for creating profiles for most floor coatings
and surfacings. Other sizes are also available. S-230 and S-
280 produce profiles matching ICRI CSP 3. S-330 and S-390
produce profiles matching ICRI CSP 5.
Striping or double exposure occurs where successive
passes overlap, producing striations that transmit through the
coatings and surfacings applied in insufficient thickness to fill
these irregularities. Any blast pattern in the substrate is usually
visible through clear coatings.
Trained and experienced operators can operate equip-
ment to minimize the effects of striping, but the blast patternwill usually remain to some degree. Unless otherwise speci-
fied, coating materials should be applied as described in the
manufacturer's instructions to achieve the specified thickness
and surface finish, and fill the blast pattern.
The work area should be cordoned off, and all personnel
in the work area should wear suitable eye protection and per-
sonal protective equipment as required. All stray shot should
be removed from the substrate surface prior to application of
coatings and surfacings. Magnets or magnetic devices may be
used to pick up stray shot. Particular attention should be paid to
removing accumulated shot from joints, cracks, and holes. The
surface should then be swept, vacuumed, and finally cleaned
with a floor scrubber. Errant or stray shot can accumulate underequipment shrouds.
B.8.4 Scarifying:Scarification is generally a dry prepara-
tion process used alone or in conjunction with other preparation
methods. Scarifiers and related equipment are available in a
large variety of types and sizes. All operate from rotary ac-
tion cutters assembled on rods mounted at the perimeter of a
drum rotating at high speed. This method can be used to clean
concrete and remove high spots and adhesives, as well as to
remove brittle coatings and surfacings, and to produce profile
ranges matching ICRI Replicas CSP 4 through 9.
Scarification, especially when using larger walk-behind
units, is an aggressive preparation method that can create
microcracking in the concrete substrate. The rotary action of
the cutters impacting the surface at right angles fractures and
pulverizes the concrete in varying degrees. Scarifying, especially
with larger equipment, generally produces a striated pattern in
the concrete surface. Deeper striations are more evident in high
points of the concrete surface. Microcracking can reduce bond
strength between substrate and overlay materials. Scarification
followed by other methods such as shot blasting can reduce
or eliminate these detrimental effects.
Scarifiers, depending upon size and cutter type, can ef-
fectively remove and profile concrete from light surface profiling
to depths of 1/2 inch (13 mm). Removal depths greater than
1/8 inch (3 mm) are generally accomplished in multiple passes.
Portable, hand-held scarifiers and smaller walk-behind units
are often used to trim around areas otherwise inaccessible to
shot blast equipment, such as around pipes and vertical edges.
Scarifiers of any size generate dust; however, most units of
any size are available with vacuum attachments that should
be used. Cutter teeth are available in different compositions,
sizes and configurations that directly impact efficiency and
performance. Equipment manufacturers should be consulted
for appropriate use.
B.8.5 Other surface profiling methods:Other preparation
methods that may be appropriate for preparation and profiling
of concrete substrates, such as needle scaling, scabbling, high
and ultrahigh pressure waterjetting, and flame blasting, may
be appropriate for use in certain floor preparation applications.
This document recognizes their uses, but will not address themindividually. Refer specifically to ICRI Guideline 03732:
Needle scalingimpacting the surface with pointed
tips of a bundle of steel rods contained by a steel tube
and pulsed by compressed air.
Scabblingimpacting the substrate at right angle with
piston-driven cutting heads to create a chipping and
powdering action, driven by compressed air.
High and ultrahigh pressure waterjettingwater sprayed
at pressures above 10,000 psi (70 MPa) SSPC-SP
12/NACE No. 5 describes this type of cleaning.
Flame blastingcombining oxygen and acetylene to
produce a flame that is passed at a given height and
rate over the substrate.
B.9 Surface Preparation for Specific Coatings and
Surfacings Categories
Section B.8 provided general guidance for surface prepara-
tion and rehabilitation for all floor coating and surfacing systems.
This section provides preparation guidelines for individual
categories. In relative scale, thinner coatings and surfacings
generally require more attention to and rehabilitation of surface
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imperfections and general planarity than do thicker surfacings.
Finished installations of thinner overlays will readily reveal
surface imperfections and other substrate irregularities.
B.9.1 Thick Film Floor Coating Systems: Thick film floor
coating systems generally range in thickness from 2060 mils
(5001,500 m). In sections of substrate where the thick film
floor coating system is intended to terminate along edges of ad-
jacent horizontal surfaces, termination edges should be sawcut
as described in Section B.3. Examples of horizontal termination
edges are doorways, openings and at in-floor perimeter work
limits shown on drawings or described in specifications. Areas
where coatings will terminate against drains, trench drains and
other objects should be sawcut. The minimum specified coat-
ing thickness should be maintained at the limits of the work, so
that coating will be flush with adjacent and adjoining finished
surfaces. The repair area should maintain the surface planarity
of the surrounding existing substrate, without depressions or
humps. The edges of repairs should be at the same elevation
as adjacent existing substrate. Holes, gouges and other similar
imperfections should be filled prior to coating. Depending upon
the thickness of the thick film floor coating system, profiling
techniques described in Section B.8 should result in the follow-
ing concrete surface profiles in accordance with ICRI Guideline
03732:
Finished coating thicknesses of 2050 mils (501,250
m) should match ICRI Replicas CSP 35.
Finished coating thicknesses of 5060 mils (1,250
1,500 m) should match ICRI Replicas CSP 46.
Surface profiles greater than those described may require
material to be applied in increased thickness to hide profile
transmitted through finished coatings.
B.9.2 Self-leveling Flooring Systems:Self-leveling floor-
ing systems generally range in thickness from 30 mils (75 m)
to 1/8 inch (3 mm), but can be applied in greater thicknesses.
Recommendations in Section B.3 regarding terminations, saw-
cuts and keying should be followed, as should recommendations
in B 9.1 regarding substrate elevation requirements and repair
of surface imperfections. Depending upon the thickness of the
thick film floor coating system, profiling techniques described
in Section B.8 should result in the following concrete surface
profiles in accordance with ICRI Guideline 03732.
Finished coating thicknesses of 2050 mils (500 1,250
m): ICRI Replicas CSP 35.
Finished coating thicknesses of 50 mils1/8 inch (1,25m3 mm): ICRI Replica CSP 46.
Finished coating thicknesses of 1/8 inch1/4 inch (36
mm): ICRI Replicas CSP 5 9.
Surface profiles greater than those described may require
material to be applied in increased thickness to hide profile
transmitted through finished surfacings.
B.9.3 Slurry Flooring Systems:Slurry flooring systems
are generally resin-rich systems filled with aggregates larger
than those in self-leveling systems, and are generally applied in
thicknesses from 60 mils to 1/8 inch (1,500 m to 3 mm). Rec-
ommendations in Section B.3 regarding terminations, sawcuts
and keying should be followed, as should recommendations in
B 9.1 regarding substrate elevation requirements and repair
of surface imperfections. Depending upon the thickness of the
thick film floor coating system, the profiling techniques described
in Section B.8 should result in the following concrete surface
profiles in accordance with ICRI Guideline 03732:
Finished coating thicknesses of 2050 mils (500 1,250
m): ICRI Replicas CSP 35.
Finished coating thicknesses of 50 mils 1/8 inch (125
m3 mm): ICRI Replicas CSP 46.
Finished coating thicknesses of 1/8 inch1/4 inch (36
mm): ICRI Replicas CSP 59.
Surface profiles greater than those described may require
material to be applied in increased thickness to hide profile
transmitted through finished surfacings.
B.9.4 Broadcast Systems:Broadcast systems generally
range in thickness from 20 mils to 1/4 inch (500 m to 6 mm).
Recommendations in Section B.3 regarding terminations, saw-
cuts and keying should be followed, as should recommendations
in Section B.9.1 regarding substrate elevation requirements
and repair of surface imperfections. Depending upon the thick-
ness of the thick film floor coating system, profiling techniques
described in Section B.8 should result in the following concrete
surface profiles in accordance with ICRI Guideline 03732:
Finished coating thicknesses of 2050 mils (5001,250
m): ICRI Replicas CSP 35.
Finished coating thicknesses of 50 mils1/8 inch (125
m3 mm): ICRI Replicas CSP 46.
Finished coating thicknesses of 1/8 inch1/4 inch(36 mm): ICRI Replicas CSP 59.
Surface profiles greater than those described may require
material to be applied in increased thickness to hide profile
transmitted through finished surfacings.
B.9.5 Mortar Flooring Systems:Mortar flooring systems
are generally applied in thicknesses of 3/16 to 1/2 inch (5 to
13 mm). Minor substrate irregularities described in Section
B.3 are generally overcome by application of mortar flooring
systems, due to the thickness of the mortar and its subsequent
compaction. Recommendations in Section B.3 regarding ter-
minations, sawcuts and keying should be followed, as should
recommendations in Section B.9.1 regarding substrate eleva-tion requirements. Humps and high points could cause mortar
to be applied in insufficient thickness to maintain the planarity
of the surface. Depending upon the thickness of the mortar
flooring system, the profiling techniques described in Section
B.8 should result in a finished coating thickness of 3/16 to 1/2
inch (5 to 13 mm) [see ICRI Replicsa CSP 59].
B.9.6 Spray-applied Flooring Systems:Spray-applied
flooring systems are generally applied at a thickness from 20
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mils to 1/4 inch (500 m to 6 mm) or greater, depending on the
resin type. Recommendations on repair of surface imperfec-
tions, terminations, sawcuts and keying in Section B.3 should
be followed, as well as recommendations in B.9.1 regarding
substrate elevation requirements. Depending upon the thick-
ness of the floor coating system, profiling techniques described
in Section B.8 should result in the following concrete surface
profiles in accordance with ICRI Guideline 03732:
Finished coating thicknesses of 2050 mils (5001,250
m): ICRI Replicas CSP 35.
Finished coating thicknesses of 50 mils1/4 inch (1,250
m6 mm): ICRI Replicas CSP 46.
Surface profiles greater than those described may require
material to be applied in increased thickness to hide profile
transmitted through finished coatings or surfacings.
B.9.7 Membranes and Membrane Flooring Systems:
Membranes and membrane flooring systems are generally ap-
plied at thicknesses from 20 mils (500 m) to 1/4 inch (6 mm)
or sometimes greater. Recommendations on repair of surface
imperfections, terminations, sawcuts and keying in Section B.3
should be followed, as well as recommendations in Section
B.9.1 regarding substrate elevation requirements.
Depending upon the thickness of the floor coating system,
profiling techniques described in Section B.8 should result in
the following concrete surface profiles in accordance with ICRI
Guideline 03732:
Finished coating thicknesses of 2050 mils (500 1,250
m): ICRI Replicas CSP 35.
Finished coating thicknesses of 50 mils 1/8 inch (125
m3 mm): ICRI Replicas CSP 46.
Finished coating thicknesses of 1/8 inch1/4 inch (36
mm): ICRI Replicas CSP 59. Surface profiles greater than those described may require
material to be applied in increased thickness to hide profile
transmitted through finished coatings or surfacings.
B.10 Startup Procedures
B.10.1 Facility and Environmental Conditions:Prior to
daily start-up, facility and environmental conditions should com-
ply with specification and coating or surfacing manufacturers
requirements. Leaks, including those from pipes and equip-
ment that could interfere with coating or surfacing operations,
should be stopped, plugged or diverted away from the work.
Doors and other ingress/egress openings that could change oralter environmental conditions if opened or left open should be
barricaded or show proper signage indicating the doors are to
remain closed. Substrate and air temperatures should comply
with specifications and manufacturers requirements during
application and cure of applied materials. Relative humidity and
dew point requirements should comply with specifications and
manufacturers instructions during application. Most coatings
require the substrate surface temperature to be at least 5F
(3C) above the dew point temperature. Whenever possible,
installations should be done after a building has reached its
operating temperature with the HVAC in operation for at least
one week. The results of all environmental testing and r