SURFACE PREP

The principles for surface preparation for Dura-Kote Metallics are aligned with other coatings systems placed on concrete and remain constant; the substrate must be:

1. Clean: The surface must be free of dust, dirt, oil, grease, paints, glues, sealers, curing agents, efflorescence, chemical contaminants, rust, algae, mildew & other foreign matter that may serve as a bond breaker or prevent proper adhesion. To remove coatings, paint, sealers, glue from concrete, etc. best results are achieved through diamond grinding or shot blasting.
2. Cured: Any concrete must be sufficiently cured to have complete hydration, approximately 28 days depending on temperatures & humidity.
3. Sound: No system should be placed on flaking or spalling concrete. If the surface is delaminating, or divots are present; then diamond grinding, shot blasting, or other mechanical means should be used to remove the delaminating areas. Depending upon size of area, patching may be required prior to application of Dura-Kote Metallics. Flash Patch or Deep Level is an excellent choice as a patching product to complement the system. Refer to their respective spec. sheets. Also, cracks my require treatment: evaluate crack as static or structural to set expectation of treatment. Refer to spec. sheet on SCT-22 Crack and Spall Treatment.
   Construction Joints in concrete may have sufficient movement to “telegraph” through the Dura-Kote Metallics. Large expansive slabs should have planned appropriate flexible caulks to allow for this movement and prevent bridging of Dura-Kote Metallics across either side of the construction joint.
4. Profiled: For a proper bond, the surface of concrete must be opened up or roughed up to feel like 80 – 120 grit sandpaper. This profile is best accomplished through diamond grinding or shot blasting. Proper profile should follow the standard established by the International Concrete Repair Institute (ICRI) Technical Guideline no. 03732 for Concrete Surface Profile (CSP). The established profile is categorized as CSP-2 or CSP-3.
5. Limit Moisture:Since Dura-Kote Epoxy 100 is not vapor permeable and due to the uncertainty of vapor barriers placed beneath concrete, testing prior to application is appropriate.
   • Plastic sheet test (ASTM-D-4263) can often identify excessive moisture vapor transmission. Tape all 4 sides of an 18” (45 cm) square of clear plastic to the slab and leave in place for 16 hours. Any condensation formed or darkening of the slab beneath the plastic indicates the surface is too wet for polyurethane.
   • Calcium Chloride test (ASTM-F-1869) will quantify the amount of moisture that is transmitted to surface of the slab. The moisture measurement is expressed in terms of pounds (kg) per 1,000 ft² (m²) per 24 hours. Measurements that are in excess of 3 pounds per 1,000 ft² (1.4 kg per 100 m²) over 24 hours are too wet for Epoxy 100. Follow directions of test kit manufacturer.

Note: these observations and measurements may be inherently flawed as they are “snapshots in time”. These tests serve only as guidelines.

TEMPERATURE/CURE

Avoid application on extremely cold or hot days or during wet, foggy weather. Basic rules include:

• Apply with ambient and surface temperatures ranging above 50°F (10°C) and below 90°F (32°C) and that will remain within ranges for at least 12 hours following application.
• Surface temperature must be a minimum 5°F (3°C) above dew point.
• Relative humidity should be below 75%.

Cure Rates @ 77°F (25°C)                         Cure Rates @ 50°F (10°C)

Dry to touch = 4 - 5 hrs.                             Dry to touch = 18+ hrs.

Light traffic = 16 hrs.                                  Light traffic = 30 hrs.

Full cure = 5 – 7 days                                 Full cure = 14 days

APPLICATION

Planning

1. Select appropriate PPE (personal protection equipment). Provide adequate ventilation. Refer to MSDS.
2. Work across the narrowest dimension of an area where practical.
3. Work to an exit from wet product.
4. To track coverage rate for each 3 gal. (11.4 liter) kit, after establishing room dimensions, before mixing commences, place a short piece of masking tape on the wall to correspond to the “distance” one kit should cover. Coverage rate should be 40 – 70 ft² per gal. (3.7 – 6.5 m² per 3.8 liter) or 23 – 40 mils. This coverage rate will create the 3-D reflective properties desired. Less epoxy millage is substandard; more epoxy millage is wasteful.

Mask all areas requiring protection; product will stick to just about everything.

Primer Coat

While not required, a black or very dark primer coat is the most popular selection due to the property of light absorption that enhances the reflectivity of Dura-Kote Metallics. Primer coats may be either Dura-Kote Pigmented Epoxy 100 or Dura-Kote Pigmented Epoxy WB. Some applicators may elect to use Dura-Kote Pigmented Epoxy WB for its simplicity in placement and increased square footage coverage, as it is applied in a thinner millage. For floors having numerous small holes or divots (e.g. blow-outs from carpet tack strip), Dura-Kote Pigmented Epoxy 100 can fill and “self-level” across the areas that would otherwise require patching, as it can be applied in much thicker millage. For specific directions on primer coat refer to the appropriate spec. sheet. After primer coat has dried and cured sufficiently (approximately 8 – 10 hours) the application of the metallic coat is ready

Metallic Coat

1. Clean: The primer coat should be screened with a 100 grit sanding screen on a rotational floor machine. This scuffing will ensure not only a good bond between coats, but also eliminate any debris or dust particulates that may have settled onto the primer coat as it was curing. Follow screening with vacuuming. Follow vacuuming with a micro-fiber wipe with denatured alchohol
2. Mixing and handling:
   • Dura-Kote Epoxy 100 is the carrier medium for Dura-Kote Metallics.
   • Organize mixing station that neither has to relocate, nor block the progress of application. Staging is critical so that Part A and part B are not confused with one another or mixed too far in advance. Once A and B are mixed, the catalyzed product should be placed on the floor immediately. If left in the pail too long, product will cure at an accelerated rate rendering it useless.
   • Pour 2 parts A into appropriately sized vessel (usually 5 gal. [18.9 liter] pail for the 3 gal. [11.4 liter] kit). Exercise care to avoid pouring product down the sides of the pail, as this will be difficult to mix with part B
   • Pour 1 part B into the same pail over the 2 parts A. Again exercise care to avoid pouring product down the sides of the pail.
   • Do not leave pail upside down to drain onto floor. Any unmixed portion of A or B that may have accidentally been placed onto side of pail can now drain down onto the floor, creating a spot that will not cure.
   • Mechanically mix both parts A and B with “Jiffy” style mixer blade for 1 minute at medium speed. (Jiffy mixer at medium speed will help prevent air entraining)
   • Shake the container of Dura-Kote Metallicss and empty the entire container into the epoxy. Exercise care to empty container into the liquid and not onto the sides of the pail.
   • Mechanically mix for 3 minutes with “Jiffy” style mixer blade
   • Pour contents completely out in a fairly long trail for application. Any unused portion left in the pail will cure at an accelerated rate rendering it useless.
   • Do not leave pail upside down to drain onto floor. Any unmixed portion of A or B that may have accidentally been placed onto side of pail can now drain down onto the floor, creating a spot that will not cure.
   • Clean out or replace mixing pails and mixer blades in a reasonable fashion, so that the chemistry of A and B remain consistent, especially over large projects.
3. Spreading:
   • Spiked shoes are required throughout application.
   • Select spreader
     • Notched squeegee or gauge rake may be appropriate.
     • Roller ranging in nap size from mohair to 3/8” may be appropriate.
     • Rollers should be premium quality with phenolic core
     • “De-fuzz” roller by wrapping tightly with masking tape and removing tape.
     • Large areas may require 18” rollers and wider squeegees.
   • Spread product evenly over area. Flatten the poured out trail into place, as it “self-levels.” Areas adjacent to walls may be “cut in” by brush.
   • Backroll the metallic coat after achieving the appropriate coverage, begin progressively backrolling First Coat.
   • Randomly swirl the metallic coat with a smaller roller in no particular fashion. The swirling motion will “soften” as the pigments settle into a pleasing patina. Working time for this process is approximately 15 – 20 minutes.
   • Time the mixes so that stages are consistently aligned. For example, if the first 3 gal. (11.4 liter) kit of metallic coat was placed and randomly swirled within 10 minutes, the second 3 gal. (11.4 liter) kit should be placed in the same time frame so that they would not appear drastically different.
   • Dry and cure sufficiently to proceed to next step (approximately 8 – 10 hours).

Finish Coat For superior abrasion and chemical resistance the Metallic Coat should be protected by a Finish Coat. There are several choices that have varying advantages:

• Dura-Kote Polyurethane SB (gloss) – high gloss
• Dura-Kote Polyurethane WB (gloss) – low VOC
• Dura-Kote Polyurethane WB (satin) – tone down the gloss
• Dura-Kote PFC-120 – quick dry
• Dura-Kote PFC-180 – quick dry, moderate build

The Metallic Coat should be screened with a 100 grit sanding disc on a rotational floor scrubbing machine. This scuffing will ensure not only a good bond between coats, but also eliminate any debris or dust particulates that may have settled as the primer coat was curing. Follow screening with vacuuming. Following vacuuming with a micro-fiber wipe with denatured alcohol or acetone.

For specific directions on finish coat refer to the appropriate spec. sheet.

Slip Resistance

Two recognizeed US agencies have issued directives on minimum coefficient of friction, OSHA (Occupational Safety and Health Administration) and Department of Justice through the ADA (Americans with Disabilities Act). ADA is the more stringent of the two. ADA directs that accessible walkways have a minimum coefficient of friction of 0.6. Ramps have been directed to be 0.8. The applicator assumes the responsibility to meet these standards. Areas that may become wet, oily, or greasy require special attention. Refer to spec. sheets on SureGrip (Additive) and its accompanying coefficient of friction table.

Suitability Sample

Due to condition specific sites, always prepare an adequate number of test areas. Wear protection system and aesthetic suitability for products' intended use should be included. On site sample approval is especially critical on substantial, heavy traffic situation or custom coloration.

Clean-Up

Before Dura-Kote Metallics dry; spills and tools can be cleaned up with a solvent such as xylene or acetone.

Disposal

Contact your local government household hazardous waste coordinator for information on disposal of unused product. Upon curing, left over catalyzed product is not hazardous.

Limitations

• For use by trained professionals that have read the complete SDS.
• Product is strictly for interior use, upon well drained concrete slab with appropriate vapor barrier, subject to no hydrostatic pressure.
• When masking use caution while taping to a floor that is not completely cured, especially at edges, as delamination may occur.
• Protect from metal wheel traffic and some furniture where point of contact may be damaging.
• Chemicals used in tire manufacturing may be detrimental to all sealers from vehicular parking.