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PDA Europe 2014 Annual Conference – Krakow, 5-7 November
Case Study:
Site Applied Polyaspartic
Garage Floor Coating
• From Great Raw Materials Come Great Coatings
Steven Reinstadtler, Bayer MaterialScience LLC, USA
presented by Karl H. Wuehrer , Bayer MaterialScience AG, D
PDA Europe 2014 Annual Conference – Krakow, 5-7 November
Case Study: Site Applied Polyaspartic Garage Floor Coating
Agenda Introduction to Market Area
The Technology: Polyaspartic Review
Original Site and Surface Preparation
Original Coating Procedure and Application
Case History: Observations
Applications for Other Adjacent Markets
Questions and Answers
PDA Europe 2014 Annual Conference – Krakow, 5-7 November
Case Study: Site Applied Polyaspartic Garage Floor Coating
Introduction to Market Area
During a lean economy, people want to enjoy more usable space in
a clean, professional looking area without purchasing a new home
Protects concrete from contaminates
• Road Salt: Can cause spalling and general concrete
degradation
• Motor Oil/Antifreeze: Can stain surface and get tracked into
home later
Provides aesthetically pleasing space
• Decorative finish brightens area and adds color
• Protects against hot tire staining of concrete
• Expands usable space in a home
Residential Garage Floor Market Drivers
PDA Europe 2014 Annual Conference – Krakow, 5-7 November
Case Study: Site Applied Polyaspartic Garage Floor Coating
Polyaspartic Coatings: High build, fast curing floor coatings
with excellent clarity, gloss and longevity
The Technology – Polyaspartic Review
“Paint on Steroids”
• Many decorative floor coatings are less than 4
mils thick
• Polyaspartic technology allows for thick, high
build finishes
• The saying, “Like watching paint dry” means
more labor time
• Cure times are greatly improved and allow for
faster return-to-service
• Proven 15+ year record in industrial
maintenance applications
PDA Europe 2014 Annual Conference – Krakow, 5-7 November
Case Study: Site Applied Polyaspartic Garage Floor Coating
The Technology – Polyaspartic Review
Chemistry:
2K aliphatic polyurea based on polyaspartic resins and aliphatic
isocyanates
OCN
NCO Polyaspartic Resins Aliphatic Isocyanate
React to form
A Polyaspartic Coating
PDA Europe 2014 Annual Conference – Krakow, 5-7 November
Case Study: Site Applied Polyaspartic Garage Floor Coating
The Technology – Polyaspartic Review
Benefits:
• Excellent durability
• Fast return-to-service time
• High build per coat
• Labor savings
• VOC compliance
• Extends application season
• Excellent „color pop‟ on
decorative stained floors
Limitations:
• Difficult to downgloss
• Smaller batches must be
mixed
• Two component requires a
mixing step
PDA Europe 2014 Annual Conference – Krakow, 5-7 November
Case Study: Site Applied Polyaspartic Garage Floor Coating
The Technology – Polyaspartic Review
Typical Characteristics:
• Excellent color/gloss retention
• Dry Film Thickness: 125 – 375 µm.
• Hardness: 60 to 80 Shore D
• Mix ratio: 2:1 to 1:1 by volume depending on formula
• Working time: typically 30-60 min. at 23°C/ 50% RH
• VOC: near zero to 100g/L
• Taber Abrasion: 25 - 60mg (CS-17)
• Elongation at Break: 4 - 100%
• Dry Time: 2 hours (Gardner Circular – 23°C/ 50%RH)
PDA Europe 2014 Annual Conference – Krakow, 5-7 November
Case Study: Site Applied Polyaspartic Garage Floor Coating
Original Site and Surface Preparation
Surface prep is key to any concrete floor coating job
Site logistics was considered first: Location of access points, switches, day joints,
and drains were noted. Temperature and humidity noted.
Existing slab was inspected: Contractor looked for cracks, spalling, porosity,
soaked-in contaminants. Oil or coolant stains were cleaned.
Surface grinding starts: Contractor found the concrete to have a high hardness so
extra weight was added to the machine.
Relief joints were cleaned out and filled: Joints were ground in order to enhance
adhesion then were filled with polyurea caulk
PDA Europe 2014 Annual Conference – Krakow, 5-7 November
Case Study: Site Applied Polyaspartic Garage Floor Coating
Original Site and Surface Preparation
Page 9
Concrete Surface Grinding: - Yields a consistent, sharp profile
- Doesn‟t micro-fracture the surface like blasting
- Doesn‟t leave residual contaminates like acid etching
HTC 500 Planetary Grinder
First Pass:
1820 Grit Diamonds
Second Pass:
3040 Grit Diamonds
Final Profile: ICRI CSP 2-3
PDA Europe 2014 Annual Conference – Krakow, 5-7 November
Case Study: Site Applied Polyaspartic Garage Floor Coating
Original Site and Surface Preparation
Page 10
Joint Filler and Repairs:
- Polyurea joint filler allowed low temperature cure and fast trimming
- Need balance of elongation, hardness, and compressive strength
- Eliminates area for dirt accumulation – cleaner look
Two Component
Electric Drive Caulking
Gun
- Aliphatic Polyurea
Joint Filler
- Trimmed at 15-20
min.
PDA Europe 2014 Annual Conference – Krakow, 5-7 November
Case Study: Site Applied Polyaspartic Garage Floor Coating
Original Coating Procedure and Application
Page 11
Coating System Build Up
Gray Polyaspartic Basecoat: Seals and bonds to prepared concrete surface
Broadcast of Decorative Paint Chips: Adds depth to decorative element
Clear Polyaspartic Topcoat: Locks the look in under a light stable finish
Process was applied to one half of
garage first, then the other half
PDA Europe 2014 Annual Conference – Krakow, 5-7 November
Case Study: Site Applied Polyaspartic Garage Floor Coating
Original Coating Procedure and Application
Basecoat: 3/32” notched squeegee, back rolled with 3/8” nap roller, 8-12 mils WFT
Decorative Chips: Full broadcast into wet basecoat, 1/8”-1/4” three-color-blend chips
Topcoat: 3/32” notched squeegee, back rolled with 3/8” nap roller, 10-12 mils WFT
PDA Europe 2014 Annual Conference – Krakow, 5-7 November
Case Study: Site Applied Polyaspartic Garage Floor Coating
Original Coating Procedure and Application
Job Completed Late Fall 2010: 80 m² garage space, South facing site
Air Temperature was 2ºC, concrete floor temperature was 7ºC
- One garage door open during application for ventilation
- Snow flurries present during the installation!
After applying the basecoat and chips, the floor cured for 1.5 hours
- Chipped finish was dragged with heavy bar
- Excess chips were vacuumed up
The clear topcoat was allowed to cure before re-entering the jobsite:
- After two hours the floor accepted foot traffic
- After six hours, vehicle was parked in garage
Additional Project Details:
PDA Europe 2014 Annual Conference – Krakow, 5-7 November
Case Study: Site Applied Polyaspartic Garage Floor Coating
Case History: Observations
Page 14
Site Observations: 3.5 years after installation
• 95%+ gloss retention – At garage opening
• 100% color retention – At garage opening
• No hot tire staining – Bay 1 contains sports car, performance tires
• No hot tire pick up – Bay 2 contains heavy off-road vehicle
PDA Europe 2014 Annual Conference – Krakow, 5-7 November
Case Study: Site Applied Polyaspartic Garage Floor Coating
Page 15
Site Observations: 3.5 years after installation
• No chemical staining – Vehicle and lawn mower oil easily wiped off
• No road salt damage – Northeast location means salt in winter
• No cracking or blistering – Coating is intact over filled joints
Case History: Observations
PDA Europe 2014 Annual Conference – Krakow, 5-7 November
Case Study: Site Applied Polyaspartic Garage Floor Coating
Homeowner Observations: 3.5 years after installation
“It’s nice to be able to hose the salt and road ash down the drain”
“ I’ve used the new space as the eating area for a communion and
confirmation party – and I’m not embarrassed”
“Seamless floor is a plus since there isn’t that joint that collects dirt and
leaves, easier to sweep up”
“I feel like I put on an addition to the house”
Case History: Observations
PDA Europe 2014 Annual Conference – Krakow, 5-7 November
Case Study: Site Applied Polyaspartic Garage Floor Coating
Applications for Other Adjacent Markets
Page 17
• Parking Decks: Fast cure means shorter return-to-service time
and less revenue loss
• Commercial Space: Hotels and restaurants like the decorative
finishes and quick installation
• Stadiums and Other Venues: Preferred for gloss and color
retention as well as cleanability and durability
- Similar areas have similar needs -
PDA Europe 2014 Annual Conference – Krakow, 5-7 November
Case Study: Site Applied Polyaspartic Garage Floor Coating
Bayer MaterialScience AG
CAS
Steven Reinstadtler, USA
Karl Wuehrer, D
PDA Europe 2014 Annual Conference – Krakow, 5-7 November
10% sovent
Mainly Co-resin
lower reactivity
NH
1220
NH
1420 NH
1520
NH
2850XP
Lower viscosity
higher reactivity
Lower viscosity
lower reactivity
NH
1521
Desmophen® Type Supply form Equivalent weight Viscosity [mPas]
Gel Time
NH 1520 Aspartic 100% 290 1200 8 h
NH 1521 Aspartic 90% in BA 326 160 8 h
NH 1420 Aspartic 100% 279 1000 1 h
NH 1220 Aspartic 100% 230 ≤ 100 < 5 min
NH 2850 XP Aspartic 100% 290 100 1.5 h
Back up: Product range Polyaspartic Coatings
PDA Europe 2014 Annual Conference – Krakow, 5-7 November
Back up: Product range Polyaspartic Coatings
Desmodur® Type Supply form
NCO content
Viscosity [mPas]
UV-stable
N 3600 Trimer 100% 23.0% 1200 yes
N 3800 PES-Prepolymer 100% 11.0% 6000 yes
N 3900 Asymetric Trimer 100% 23.5% 730 yes
E XP 2599 PET-Prepolymer 100% 6.0% 2500 no
Flexible N
3900
N
3600 N
3800
Hard
E XP
2599
Flexible
Viscosity decrease