Epoxies are polymer materials that begin life as liquids and are converted to the solid polymers by a chemical reaction. An epoxy-based polymer is mechanically strong, chemically resistant to degradation of the chemical elements in the solid form & highly adhesive during conversion from liquid to solid. There are a wide range of basic epoxy chemicals from which an epoxy system can be formulated. Epoxies are known for their excellent adhesion, chemical and heat resistance, good to excellent mechanical
properties & particularly good electrical insulating properties. Almost any property can be modified. Epoxy floorings are surfaces that comprise of multiple layers of epoxy that is applied to a floor of depth varying from 300 microns to 4mm or above. Following is a description for the application of a general-purpose epoxy floor using Ressi EPO Tough Might. This flooring can be applied up to a thickness of 4mm
Step 1: Assessment of the surface
It is essential to assess the surface on which the application of an epoxy flooring is suggested. If the surface is not ready to accept the subsequent products, it is recommended to prepare a floor which is appropriate to receive the proper epoxy flooring treatment. Usually for freshly laid concrete, it is recommended to make sure that the concrete is at least 28 days old and has a moisture content which is less than 5%. It is also to be ensured that the concrete Is levelled and reasonably smooth.
Note: Generally, better the surface, better the finishing of the subsequent layer of finishing epoxy. It is recommended to keep the floor as levelled and straight as possible, even if there is a slope, it is recommended to make sure that the surface is as straight as possible in a slope.
Step 2: Crack filling of the floor
Once the surface has been laid, and properly prepared, there should not be any cracks over the floor. Incase if there are cracks on the floor due to minor shrinkage or some usage of the floor crack filling should be done using Ressi EPO Crack Fill. Once the relative cracks have been identified over the floor it is essential to prepare the floor for the subsequent treatments of Flooring Epoxy Crack Fillers. If the hair line cracks are less then 2mm wide, it is recommended to slightly open the cracks using a chisel hammer or any other appropriate tools. Once the cracks have been opened, it is recommended to clean all the loose debris from the floor and cleaning the cracks with a wet brush and some water. Once it has been clean make sure that the floor itself is dry. Cleaning of the surface is essential as poor cleaning may result in the debonding of the crack fillers applied on the surface. It is also essential to make sure that the floor surface is free from any dust, oil, grease, laitance, or any other material which may result in the debonding of the crack filling material. Once the crack has been opened and proper surface has been prepared, the surface is ready to take in the subsequent crack filling of Ressi EPO Crack Fill.
Ressi EPO Crack Fill is a three-component epoxy-based crack filler. It contains Base Resin (Part A), Hardener (Part B) and Filler component (Part C). It is essential that the ratios of the resin and Hardeners should always be consistent (1 part Resin and 0.8 Parts Hardener). The filler ratio can be adjusted as per the requirements of the crack filler.
If the cracks are deep (above 4mm in depth), the filler ratio can be adjusted to make the Ressi EPO Crack Fill more flowable so that it can penetrate within the cracks, if the cracks of the floor are less then 4mm deep, the filler ratio can be adjusted to make a putty like paste of Ressi EPO Crack Fill material so that it can easily be applied with a scrapper.
Step 3: Surface Grinding and preparation
Surfaces should be free from grease, oil, chemical contamination, dust, laitance, and loose concrete. Appropriate surface preparation equipment such as shot blast, Scarified or grinder must be used to obtain sound substrate. Surfaces which show any traces of oil must be degreased with a chemical degreaser prior to any surface preparation or grit blasting. Uneven concrete should be levelled to produce flat surfaces. New concrete floors must be at least 28 days old prior to application. Moisture content of the concrete or cementitious floors must be less than 5%. Expansion, control & isolation joints should be carried through floors filled with a suitable sealant. Please refer to the application video for epoxy flooring for further guidance.
Step 4: Application of Ressi EPO Primer.
Ressi EPO Primer is an epoxy-based Primer to be used prior to the application of epoxy flooring and coatings over concrete and cementitious surfaces. Ressi EPO Primer is an ideal material to be used in conjunction with various epoxy flooring materials. It is used as a priming coat on concrete and cementitious surfaces prior to the application of various epoxy floorings and coatings. Typical areas of applications include car parks, factory floors, food industry, kitchens, aircraft hangers, hospitals, pharmaceutical plants, warehouses etc. It can be used as a clear coat to maintain original color and appearance of substrates which are not exposed to UV rays.
Apply the material with a suitable squeegee, stiff nylon brush, roller or suitable tools working the Ressi EPO Primer into the substrate to ensure total absorption into the pinholes and voids. Spray application is also possible. Airless spray will provide faster rate of application.
Prepared surfaces should be primed using Ressi EPO Primer. The primer should be brushed into the substrate using a stiff brush or roller and allowed to become tacky (10-20mins) before the application of Ressi EPO Tough Might. The primer should be allowed to dry. If the primer has dried, additional coat of the primer should be applied and allowed to become tacky.
Step 5: Application of Ressi EPO Tough Might
Ressi EPO Tough Might is a two-component epoxy resin based heavy duty and impact resistant epoxy flooring. It is designed for trowel application in thickness between 300 microns to 4000 microns. Ressi EPO Tough Might provides a tough, high abrasion and impact resistant topping. It is used either as a coating or a screed for flooring where excellent mechanical properties with superior abrasion and wear characteristics are required. It can be used for industrial floorings, warehouses, workshops, ramps, garages, airport maintenance areas, metal processing and engineering units and areas subject heavy traffic. It can also be used as a coving or patch repair product.
Stir the base and hardener components separately. Once both components are mixed, they should be mixed thoroughly using a slow speed drill attached with paddle for at least 3 minutes (400-600 rpm) until a uniform homogenous mix is achieved. Lay Ressi EPO Tough Might over the prepared surface whilst the primer is still tacky. Spread out with a notched trowel to a uniform thickness. Level the material using appropriate trowels and tools to the desired level. Stroke with a steel trowel to achieve a sealed resin rich surface. A Spiked roller can also be used to achieve a uniform surface. At higher temperatures pot life will be reduced. For working in temperatures below 5°C Ressi EPO Tough Might may need to be put in a hot water bath. For further information, please refer the reference videos and the product technical datasheet.