Polymeric Resin Floor System from Epoxy floor coats. New flooring Approach to find solution for Commercial floor cover

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1 Rising damp Dynamic loads Reduces Construction Time Polymeric Resin Floor System from Epoxy floor coats New flooring Approach to find solution for Commercial floor cover Md Monjur Jalil B.Sc. Ho'ns in Chemistry (Fergusson College) MBA Major in Finance (IBA, DU) Suitablefor forheavy heavymechanical mechanicalloads loads Suitable RResistant e s i s t a nto t to Chemicals Chemicals C Conductive onductive Functionalfloors floors F unctional Many designs Many d e s i g n spossible possible Highquality quality room High roomconcepts concepts

2 Abstract: Commercial Floor: must be different to serve the functionality of the key activities on it. Epoxy as material: Polymeric Resin: Epoxy Paint/Coat: Floor System: Systematic approach to build the floor: from repairing/strengthening RCC or CC sub-floor, to installing floor finishing cover made of different Polymeric resins. Ideally the floor system should conform to most parameters of floor finishing covers (functionality, cost, time constraints etc.) Epoxy Paint on Concrete Surface Vs Polymeric Resin Floor Floors for different commercial activities are to be made differently. A customised floor solution couldn't be offered to customers because nearly all installers/suppliers of Bangladesh don't have technical know-how and precise resin materials available with them. Commonly served varied thickness (2-6mm) of the Epoxy Floor seems just wastage of money. Films/Coats made from Epoxides are known as Epoxy Paints. Generally it's formed by pouring & spreading liquid Epoxide components on the surface, which go into thermo setting reaction to hold on the substrate/surface in bottom, and to seal it's the top surface. Epoxy is used for many purposes such as: glue, bonding material, Concrete Crack fixing, floor finishing layers, etc. Each of the epoxy functions varies by formulating it. Polymeric resins are applied to make a floor-finishing cover on different surface (Sub-floor). Instead of using epoxides (Epoxy) in different layers, multiple layers of other genre of liquid polymer components, Formulated Epoxides, Polyurethane, Silicate, Acrylate, etc. are added. Like any other typical surface coating, two distinct types of Paints on Epoxide base are used: Primer, and top-coat(s). But in some cases, customer is severed with only "top-coat" of thick Self-level type Epoxy coat. A systematic approach of making floor-finishing cover on site. It includes too, floor surface (Old floor) repair materials &/or material to strengthen load bearing ability of the floor. The combination of polymers with dosage levels (stating minimum dosage level), and their application technologies: all make it to call Floor System. This is much different than floor painting or coating. The Polymeric Resin Floor system is made with respect to: 1. The state of the substrate: surface as material, moisture/oil content, load bearing ability, etc. 2. Functionality: the kind of key activities those would be undertaken. 3. Budget constraints 4. Allowable Time (for installation): For firms in operation its important to ensure business continuity 5. Renovation coat interval that can be maintained in future. 6. Floor for special activities such as: High Chemical (0-14 ph), Thermal (570 0 C flame), & Mechanical Movement Resistant floor. Horizontal Surface: Polymeric Resin Flooring Breathable Polymeric Resin Flooring (Roller Coat) Granule & flakes Flooring (Mosaic Like) Roller Coat or Self-level Polymeric Resin Flooring (Self-level) Self-Level Epoxy flooring Screed Polymeric Resin Flooring Zydrite Timeless flooring & Coordinated 3-D depth visualization Stone Carpeting Effect Flooring Metallic & Concrete look Silicate Surfacing Self-level Polyurethane 2/9

3 From Epoxy Coat to Polymeric Resin Floor by Remmers: A new product line for Bangladesh "All variety of Epoxy coats on floor are essentially of Polymeric type, but all Polymeric Resin floors are not Epoxy (type)!" î Polymeric Resin Floor, as a new term: Polymeric resins are thick viscous liquid of Organic or inorganic polymers, when evenly poured on subfloors, and are spread by spreader or roller make film of floor cover called Polymeric Resin Floor. The polymers go into thermosetting process to cure and to stiffen as floor top cover material. The floor system is water impermeable, and acts completely as waterproof layer to protect water absorbing cementitious surface (paten stone, or RCC slab). Unlike other conventional floor top materials, Polymeric resin floor is the most lightest (lesser weight) floor system of all. Comparing with 10,000 Ft 2 floor top, Polymeric resin floor (1 mm) weight is one fifth of the Tile floor weight (7,500 kg average). Tiles Polymeric resin floors rapidly forms a single piece of floor. Business starts days ahead of schedule if compared with Tile floor top. For large project, a well planned construction with Polymeric resin floor saves capital cost, and benefit with earnings from earlier operation. For large project with unscheduled delays are somewhat compensated for the same reason. In last two decades, Polymeric Resin Floor had become the global trend as floor top of choices, reasons are put below: Installation, repair & maintenance Minimal installation hazard. Water, & other voluminous materials not required. Repair job is easy, and can be carried out without bothering business as usual. Very easy to clean every day. Benefits Great time saving: fast surface preparation, faster installation, and fastest repair job. Benefits from early production or operation commencement. Floor aesthetics can be changed by just putting topcoats & additives to get any color, & numerous textures-designs Safety It's joint-less, most hygienic floor top. Acts as waterproof for RCC surface below. Can be achieved a customised anti-slip surface feel, variety of all 5 slip-retardant classes. Can be made Anti-static for sensitive floor. Comparing to tiles & paten stone floor, it's lightweight is never considers as load factor. Components/Materials used Polymeric Resin Floor: Various Organic or inorganic Polymers constituents major part of the floor system. Various additives are used with polymer to get enhanced load bearing ability, impact resistance, scratch resistance, variation in lustre-feel, and variation in gloss/mat level Major types of polymers used in Polymeric resin floor system are Epoxides, Polyurethane, Silicate, & Acrylate. Polymeric Resin floor can be designed & installed either by: 1. Using solely one of these categories of Resins (Epoxide, Polyurethane, Silicate, Acrylate), or 2. Using combination of layers from these base materials. In combination layers (of different Polymeric Resins), Epoxides are selected as base layer/1st layer, and the Epoxy Primer type is used. Remmers has variety of Polyurethane products, thin layer of Polyurethane is generally used as top most seal coat of the system. Epoxide: Epoxides compounds (in number of layers) to form floor top surface comprises 95% of Polymeric Resin floor in Bangladesh. Substantial volume of Epoxides is on Solvent medium and not to be used in indoor areas. Most locally available suppliers have two verities of Epoxy: Roller Coated, and Self-level Epoxy. A locally operated Multinational Paint company introduced 3mm thick SLE, but not with consistent quality level. Where as Remmers made most Epoxides use Water as medium. Water base Epoxides, penetrates deep into the surface, forms stronger bonding, are easy to handle & VOC level complies for indoor use. Remmers formulated Epoxides, which are Unique in the world: Breathable Epoxy BS 2000/3000, & Epoxy FAS /9

4 (Sole Agent of R E M M E R S B a u s t o f f t e c h n i k, Germany) Polyurethane: Polyurethane floor system, as single material, has to be in a thicker layer (minimum thickness-2 mm). Layers of Polyurethane forms highly durable floor, and are relatively expensive. Installing Polymeric resin floor from only Polyurethane material requires high skill, and market has shortage of such installer. This makes floor system to be expensive. Polyurethane coats (thin or thick) give relatively soft lustre, and serves to minimize scratches. Remmers produces all variety of Polyurethane: breathable type, thin coats, thick coat, single or double components, etc. Silicate: Silicate materials made Floor are most durable. One of the silicate floor systems were invented & patented by Remmers, a costing system that can sustain 0-14 ph level, direct flame of heat 5700 C, Heavy thermodynamic loads. Its know as Chemical-proofing of the surface. The floor top is matt; don't have soft lustre as polyurethane coat, and smooth surface as Epoxide topcoats. Silicate floors to be made in one of the 3 thickness categories, 4 mm, 6 mm, & 8 mm. Although Silicate floors are very new to Bangladesh Market, its installation is not as hazardous as thick Polyurethane floor. Acrylate: Acrylate made Polymeric floor is generally for home use and meant to withstand light load. Ancillary Materials used in Polymeric Resin Floor: Apart from the above compounds, various natural or polymer materials are used as: fillers, and visual effects variants. These materials added in intermediary coat or on topcoat for enhanced functionality as well look of the floor. Area of usage: Remmers Polymeric Resin floor system can be installed on almost any kind of difficult sub-floor. Most of the common Sub-floors as stated below: 1. RCC, made smooth by trowel finished as shown in the photos 2. Paten Stone cast, 3. Old Epoxy Coating, 4. Vinyl Floor, 5. Mastic asphalt, RCC casting, Compaction and making trowel finished surface. Sub-floor surface finishing for (1) RCC, & (2) Paten Stone Casting 6. Wooden floor, Ranges of extreme floor 7. Cork Sheets, 8. Oil soaked RCC or CC floor 9. Tile floor: Glossy tiles too 10. Mosaic floor 11. Floor in wet condition, and would be used later in wet condition 12. Damp cementitious surface, generally floor in contact with ground. Smooth Sub-floor saves money yet enhances beauty. Remmers Roller Coated floors covers millions of Large Car parks, Fork lift moving floors Industrial floors World-wide. Seal Coat of Polyurethane - thin Coat Top Coat of Epoxy - thin /thick Coat (Self-level Epoxy) Epoxy Screed With Additives: Varied LAYER THICKNESS 1. Top layer: Epoxy Smoothening putty 2. Variable thickness of Screed layer of Epoxy with graded Quartz Black Line: Epoxy Primer, in thick Coat filled with Quarts. Depending on floor functionality, this Primer can be simply Roller coated variety, or a thick coat. Sub-floor: Generally RCC or CC 4/9 Product Display: T i l o t t o m a D e s i g n S t u d i o, G u l s h a n 1, R o a d 1 3 8, H o u s e 8 A, Dhaka, Phone: , & Communication: Tel: , Fax: , i n f c a r n i v a l i n c. n e t, monjurj@carnivalinc.net

5 î Difference between Epoxy paint/coat, and Polymeric Resin Floor system: We require to understand difference between: i) Epoxy & Polymeric Resin, and ii) Coating & Flooring system. Comparison between Epoxy Coat & Epoxy Floor systems: Epoxy coats are just make-easy coat put on floor at certain fixed dosage level. Epoxy Floor system is a customised solution for individual requirement of a particular floor or different parts of the same floor. Comparison between Epoxy coat & Polymeric Resin: there is difference in material use to make floor more durable, functional, cost viable, and pleasant look. Looking at the way other companies serve Epoxy floor locally: In Bangladesh, most local companies sell Epoxide coatings only, which are imported from Countries like India, China, Malaysia, etc. These epoxy coats are generally: Other Company: Material type, compatibility, & system coordination 1. A thin layer of film with its DFT in the range of 200~250 micron (0.2 ~ 0.25 mm) thickness. Materials are epoxide in solvent media, which are coated by roller or brush: at least single coat of Primer & seal coat/topcoat is applied. Most of the Solvent based Epoxides are not to be used in indoor areas for heath hazards, high VOC content. 2. Self-levelling thick coats. These types may have different Primer and topcoat. But some of the companies work on single type of Epoxy to get thickness of 3 mm to 10/12 mm. Absence of Primer (epoxy) doesn't make the thick coat to adhere with the surface well. 3. In both Roller coated & Self-level Epoxy, others generally have limited numbers of variety of Epoxy, and use common curing agent for all kind of Roller coated Epoxy, a separate but single curing agent for all kind of Self-Level Epoxy. Finely coordinated curing agent for each product cures the resin part better, and hence floor system would have better performance. 4. Absence of performance chemicals to repair & strengthen the sub-floor surface. 5. Do not state the Product Quality Certification (health-hygiene, & durability) by independent, & internationally reliable Standardization bodies (Government or Institutes/Laboratories). How Remmers Polymeric Resin Floor Systems are served locally: Comparing with others, as we go through the points mentioned above for other companies we would find following differences. Remmers System: Material compatibility, & system coordination (Detail on floor preparation, repair, useful tools, technical know how) 1. For each type of floor, & floor conditions, Remmers have wide range of Epoxy Primer, & Epoxy Top coats. With Remmers Roller coated epoxy, layer thickness can be made from 200 micron to several centimetres. Remmers produces water based epoxy, solvent base epoxy is prohibited to use is indoor area according to different health hygiene standards followed in European (BS, German Standards, DIN, & DIEN). 2. For self level epoxy variety, Remmers Self level epoxy are present as both Primer, & Topcoat. Usage is very versatile. One can choose system as, Self-level Epoxy primer as first coat followed by roller-coated epoxy on top of it. Or Roller coated epoxy as Primer, then Self-level epoxy topcoat. Or between two types of Self Level Epoxy one can install epoxy screed layer made from Roller coated epoxy, i.e. Primer coat of Self-level Epoxy, middle layer made for Roller coated Epoxy Screed followed by another top coat of self -level 3. As of Curing Agent, Remmers fully understand how important it is to formulate curing agent for each variety of Epoxy, & Other Resin Components. Products are packed in such way that mistakes are eliminated for: i) selecting customized Hardener (for the resin), and ii) the mixing ration of those resin-hardener. Each type of two components Polymeric resin is kept a two-chamber container in specified Ratio (Resin vs Hardener). Generally Product to product curing agent is different so as the ratio of those. For Polymeric Resin Floor installation, mixing peddle, application tools etc. are also manufactured by Remmers, because Remmers Philosophy is to make a "Job Well Done" by going through all the details. 4. A good number of products & systems available for subfloor repair, & strengthening the old concrete. 5. Product system durability conforms OS 8 Guide Lines of DAfStb - the German committee on reinforced concrete. 6. 5/9

6 î A difference: Uncompensated & unique in nature Polymeric Resin floors installation requires to make a system by considering various aspects, such as type of base floor (subfloor), Functionality of the new floor, load pattern (Static vs Dynamic, Weight of rolling load, Chemical load, thermal load, conductivity, impact load, UV load, etc.), budget, delivery time, expected usable life, information on renovation coats next, etc. Other companies selling Epoxy coat seems to have scarce resources to make durable floor system. Unavailability of variety of materials, product innovations, and lack of technical know-how are major reasons for they not serving well. From above one can deduce, to cater real need of customer, companies do not have variety of material & detail working technic. Common combination of floor in terms of cost-benefit is given below: System called WDD (Water Vapour Diffusion Capable) A common floor system assuming film thickness of 0.75 to 1.5 mm for indoor area, and load sustainability for Vehicle movement- 1. Base layer of Epoxy as primer: Can be thin layer of roller coated variety, or Self level type primer. 2. Intermediate layer of Epoxy reinforced with Quartz granule: Can be thin layer or Self Level 3. Top layer of Polyurethane: Its generally roller coated. It can be single component or two components. It can be Transparent in Glossy look or Matt look. Or it can be pigmented two components of glossy or matt shine level. Optional: Sub-floor Preparation 1) Repair by Polymer or Micro Concrete, 2) Strengthening by Screed Strengthener, 3) Floor levelling by Self-level Mineral Screed (3 to 30 mm) Thin Roller Coat Remmers Germany's Polymeric Resin Floor Systems as served in Bangladesh 1st layer: Epoxy base layer (Epoxy BS 2000) 2nd layer: Epoxy Screed layer (Epoxy BS 3000) 3rd layer: Epoxy Smoothening Putty layer (Epoxy BS 3000) 4th layer: Epoxy Final layer (Epoxy BS 3000) 5/6th layer: Scratch Resistant Coats of PU ( PUR Aqua Top 1K or 2K) Options for floor feel Primer- Epoxy (On sound loadable surface) Epoxy Screed Coat With Quartz Epoxy Coat with thixotropic agent Epoxy seal coat Final Polyurethane (PU) Thin Roller Coats Options for floor feel & look (non-monolithic) <0.75mm Self-level Thin Roller Coat <0.75mm Self-level Thin Roller Coat Coat <0.75mm Self-level Thin Roller Coat Coat <0.75mm Self-level Single Component Two Components GLOSSY Options for Non-monolithic floor look Different options for varied layer thickness. Light Dynamic Load (DL) Heavy Dynamic Load Coloured heavy DL Transparent heavy DL MATT Soft feel: with thin PU layer Anti-slip: 5 Classes of it Mosaic look: Polymeric Flakes Gravel look: Colored Quartz Stone Carpet: min. Ø 5mm 6/9

7 î Unique Flooring Solutions of Remmers, made in Germany For used floor surface having variety of problems such as spill of the paten stone, cracks, oil saturation, loose consolidation of cementitious materials etc., Remmers offers number of different types of chemical products to repair sub-floor surface, and to achieve a stable load-bearing surface for next floor cover job. These coordinated product systems are so unique that no other companies have such versatile solutions made in their own production facilities. Remmers uniqueness originated from its 60 years of experience, today 450+ product-system in its basket, staffed with strong teams of 120+ scientist working on Product innovation, Application technology, and customers service. Remmers Polymeric resin floor Product-system has following units, & categories to carry different types of jobs : products for repairing, and for strengthening the surface of used/old floor Mineral (Cementitious) Self-level finishing subfloor systems verity of formulated Epoxy base products verity of Polyurethane products variety of Silicate surface coating products. 6. 2/3 types of Acrylic base products. 7. Can deliver almost any color shades of products for top coats. 8. Possible to deliver floor of varied gloss level (Silk Gloss, or Matt), Mosaic effect floor (from Polymeric flakes), Pebble stone effect (using different granules, & rounded color Quartz), concrete look, etc. Knowhow: Selecting a suitable Floor system: 7/9

8 î Common Problem and Others Solution: neither Cost effective nor time saving Moisture moves in and out of ground is a common phenomenon as of the soil type and climate of Bangladesh. Most Pre-fabricated buildings have very large floors in contact with ground. For various reasons upward moving water in form of vapour/moisture put pressure on the top floor-finishing layer. This causes blister formation on dry film of epoxy, meaning the dry film layer losses its adhesion from the ground. Due to dynamic movement on the floor, blisters on it spill-off confirming that the polymeric resin floor had lost its functionality and load bearing ability. Water or Water Vapour is involved in Most of the Processes, that Destroys Building Materials. And for floor in contact with ground, its Raising Damp that drastically shorten floors usable life. Why Blisters form on Epoxy or PVC floor? Answer: Due to moisture/vapour penetration on floor from- (i) ground in contact, and (ii) for other levels floors, Moisture & Off-gas arising for rapid construction, i.e. shorter curing-drying time of cementitious sub-floor. What are the reasons for vapour penetration? Answer: Moisture in building materials may result from below issues- Pics of Blisters on Epoxy Moisture 1) The production of the building materials: Cement Aggregate & Water binds to form Concrete or Mortar. After curing, these materials leaves moisture/vapour and off gas for approximately 6 (six) months. 2) Moisture penetrates through cracks, seepages, voids and capillaries. 3) Moisture penetrates in form of osmotic pressure, and condensation. How can we prevent Moisture ingress in building materials, specially in floor? Answer: For above reasons, preventions are given below: 1) Moisture from building materials (slr 1) all moisture & off-gases would be discharged if a long curing time can be given. 2) Repairing the Cracks, voids, etc. by high adhesive & flexible waterproofing compound(s). 3) Moisture from Capillary action, and Osmotic pressure are called "rising damp". A complete Damp-proofing course is required. How can we prevent Rising Damp? 1. All given solutions are long lasting. 2. Any of the systems would Cost nearly the same cost of the Floor top (finishing) material. 3. Time required: 21 days for Slr 1, and 7 days for Slr 2 & 3 Answer: Below are common solutions to stop moisture ingress Rising Damp: 1) Usage of thick cementitious screed layer made of a mixer constituting Portland cement & Waterproofing agent (called Polymeric Concrete). 2) Coating the surface with thick Polymer Modified Bituminous material, or PE Resin material (below a freshly casted cement screed). 3) Coating the surface by capillary blocking material (Silicate Crystals) followed by multiple coats of Sulphur resistant waterproofing grout. The available Epoxy coat would have moderate usable life if one of the above preventive measures were under taken. How other companies counteract rising damp? Any of the above preventive methods is expensive as well time consuming. And the fact that, most flooring companies in Bangladesh do not have Waterproofing materials, & technical know-how. Common solution by those companies, and the implication of such solutions are explained below: 1. Epoxy Coat sellers in Bangladesh suggest and work on thick Epoxy coats assuming that the thicker is the Epoxy coats, the more that would likely to sustain the moisture pressure from sub-floors. 2. Thick coat of Self-level Epoxy type, thickness of 3-6 mm are installed commonly to withstand the rising damp, or other moisture penetration (rapid construction) on the floor cover. 3. This principle gives a temporary solution, and it may at best retard the blister formation, i.e. delaying the process of blistering. 4. Implication of those existing solution: a. More material applied, most cost is incurred. b. Less service life, more frequent floor installation, more time & money is lost. 8/9

9 (Sole Agent of R E M M E R S B a u s t o f f t e c h n i k, Germany) î A simple Approach of Remmers to handle moisture/vapour pressure forming "rising damp": Since Preventing Moisture penetration as "rising damp" on large floor seems expensive and time consuming, Remmers Offers the market with new approach: "Water Vapour Diffusion Capable floor". This floor system has Epoxy Primer, Epoxy Top coat, and the scratch resistance Polyurethane seal coat(s) - all are diffusion capable. The floor system, i.e. Polymeric Resin Floor System of Remmers has dual roles: 1. Floor system acts as Water barrier, and 2. Floor System allows a limited moisture/vapour to diffuse on floor surface. And the quantity of moisture/vapour floor system releases is very minute to be notices. Epoxy BS 2000, BS 3000 PUR Aqua To 1K, PUR Aqua Top 2 K, PUR Aqua color top 2K î One Epoxy resin product of Remmers with multifaceted a reliable Solution for Extreme subfloor condition: Extreme sub-floor Surface 1. Oil Soaked for many years through RCC or Paten stone floor, requires a decent workable condition 2. A Sub floor surface with cracks, voids, etc. 3. A running business house, or a hospital having old broken out Tiles, most of them glossy. Requires a floor system without breaking the surface to install new... how to avoid a sure business discontinuation? 4. A wet floor of newly cast Sub-floor surface. A real challenge, with one solution: REMMERS EPOXY FAS 100 Water poured on tile placed Epoxy FAS 100 is seen not After Curing time: A strong below water losing its particles in Epoxy (SLE type) layer formed. water, water looks clear. Hammer& Chisel are required to separate the Epoxy Layer form the Tile surface. Thank you for your interest on the technology that is made available for serving you next! 9/9 Product Display: T i l o t t o m a D e s i g n S t u d i o, G u l s h a n 1, R o a d 1 3 8, H o u s e 8 A, Dhaka, Phone: , & Communication: Tel: , Fax: , i n f c a r n i v a l i n c. n e t, monjurj@carnivalinc.net