The application process of epoxy flooring requires strict control over each stage to ensure quality. Here are some key application points:
1. Surface Treatment: The newly finished industrial floor should be left undisturbed for over 28 days to allow proper curing before construction begins. Remove cement laitance, outdated paint, and all debris from the floor surface to ensure a clean base. Use K oil King degreaser to thoroughly clean oil stains, restoring the original color of the floor surface. Address water pooling issues, and ensure that wet areas are completely dry to create suitable conditions for construction.
2. Polishing and Cleaning: Utilize dust-free sweepers and large vacuum cleaners for thorough cleaning of the floor to ensure a clean construction environment. Ensure the floor surface is level, with gaps no more than 22.5mm, moisture content below 6%, and a pH value within the range of 68. Use a dust-free polishing machine to abrade the floor surface and then clean it meticulously with a vacuum to remove the dust generated. For holes and indentations on the floor surface, apply putty for filling and leveling. After the putty has dried, proceed with polishing and vacuuming.
3. Primer Application: On a clean, smooth concrete surface that has been meticulously prepared, apply a single coat of epoxy primer using high-pressure airless spray or roller coating methods. The epoxy primer has excellent penetration, so a suitable amount of thinner should be added during application to ensure the primer penetrates deeply and enhances the adhesion between the coating and the substrate. Maintain a continuous application and control the amount to achieve just the right saturation of the surface. In case of any missed spots, immediately touch them up with a brush, and make sure to sand down and clean off any excess primer from the surface before starting the next process.
4. Putty Application: After the primer has dried (approx. 4 hours, in 25°C environment), treat the floor with two coats of putty. The first coat combines 100-200 mesh quartz sand with epoxy topping and is applied evenly to enhance the floor's wear and compressive resistance. Use a dustless rolling sanding machine with sand bags to sand the first coat and vacuum clean. The second coat uses 200-270 mesh quartz sand mixed with epoxy topping and is applied in the same manner, aiming to further improve the floor's wear resistance and flatness. After sanding the second coat, vacuum clean again to ensure the floor is smooth and clean. If any pockmarks or cracks are found after both coats have dried, repair them first, then use a flat sanding machine for fine sanding to achieve ideal flatness.
5. Intermediate Layer Application: After the putty surface has been sanded and cleaned, and the temperature is 20°C with the putty fully dried for 24 hours, begin applying the intermediate layer of the floor finish. Methods such as brushing, troweling, or high-pressure airless spraying can be used, with large-scale applications recommended to use high-pressure airless spraying, ensuring the spraying pressure is maintained between 20~25Mpa. This coat will make the floor more level and also help identify and address any potential defects, providing a better foundation for the subsequent topcoat application.
6. Surface Application: After the intermediate layer of the floor is fully dry, begin the application of the epoxy floor surface coating. Methods such as troweling and high-pressure airless spraying can be used, but it is recommended to use high-pressure airless spraying for increased efficiency. Prior to coating, the intermediate layer should be sanded and dusted to ensure the surface is clean and dust-free. If the client has installed and debugged equipment after the intermediate layer has dried, causing new defects on the floor, the leveling compound should be used to level, sand, and dust clean the surface before applying the topcoat.
