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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

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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

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give any warranties, expressed or implied, nor make any representations as

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SSPC-TU 10

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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

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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


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


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.


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.



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


profiles in accordance with ICRI Guideline 03732:



Finished coating thicknesses of 50 mils 1/8 inch (125

m3 mm): ICRI Replicas CSP 46.


mm): ICRI Replicas CSP 59.




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 50 mils1/8 inch (125


Finished coating thicknesses of 1/8 inch1/4 inch(36 mm): ICRI Replicas CSP 59.




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


profiles in accordance with ICRI Guideline 03732:



Finished coating thicknesses of 50 mils1/4 inch (1,250




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 50 mils 1/8 inch (125



mm): ICRI Replicas CSP 59. Surface profiles greater than those described may require


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

Documents

Pintura TU10.2807