SURFACE PREPARATION INSTRUCTIONS: CONCRETE
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1 SURFACE PREPARATION INSTRUCTIONS: CONCRETE DEFINITION OF TERMS The terms listed will be used frequently throughout this article and listed in boldface for ease of reference. They describe, in detail, the methods, procedures and meanings that LifeLast, Inc. adheres to. Please read them carefully. DEGREASE The process of degreasing a substrate involves the removal of oil or grease-like organic or non-organic materials that could impair bonding of the coating to the substrate. Degreasing a substrate involves the use of a solvent or other cleaning agents such as ammonia, bleach, hydrochloric acid, citric acid, lye, or any other material that will dissolve or react with contaminant to remove it from the area. Common degreasers are acetone, methyl ethyl ketone, xylene, toluene, ammonia, glycol ethers, and hydrochloric acid. If the material that is used as the degreaser leaves a residue (such as hydrochloric acid or acetic acid or one of the citrus based cleaners) the residue must be removed before the coating is applied. Caution should be exercised to verify compatibility between all cleaning agents and degreasing agents used (i.e. - do not use bleach with ammonia). CLEAN Cleaning the surface of the substrate is defined as the removal of all contaminants. This is typically done with ammonia or a solvent such as acetone. Dust removal can be done with the use of a vacuum system that has a suction power of 80 psi or more. Contaminants to be cleaned or removed would include dust, dirt, residue from degreasing, waxes, oils, etc. The condition of the surface after cleaning is contaminant free. There should be no residues, oils, or dusts. Caution should be exercised to verify compatibility between all cleaning and degreasing agents used. Surface Preparation Instructions Page 1
2 PROFILE A profile is the creation of a texture on the surface of the substrate to be coated. The texture of profile is created by blasting the surface with a solid or liquid media or grinding the surface with a sanding disc. The blasting media that are preferred are as follows: 1. Steel Grit 2. Alumina 3. Garnet 4. Black Beauty 5. Green Diamond 6. Steel shot 7. Silica sand 8. Soda blasting (does not create a profile) 9. Soft media blasting (does not create a profile) The surface preparation methods for creating a profile that are preferred are as follows: (in order of preference) 1. aggregate blasting (not including silica sand) 2. shot blasting 3. abrasive wheel grinding (16 grit and larger) 4. roto peening 5. silica sand blasting 6. soft media blasting (on concrete only) LAITANCE Laitance is the weak silicatious material that is found on the surface of some concrete. The laitance is fine in texture and is the result of troweling. Repetitive troweling brings the fine sands of the concrete to the surface. The fine sands create a smooth texture but are weak in tensile strength. The removal of the laitance ensures bonding strengths that would be the maximum for that particular concrete. In some cases, bond strengths of psi are suitable, thus the removal of the laitance is not necessary. If bond strengths of 150 psi are desired, one of the two options are: 1) the removal of the laitance is not required but the use of LifeLast Primall-EP over a clean surface is, or 2) the removal of the laitance but no priming would suffice. If bond strengths in excess of 300 psi are required, then the removal of the laitance and the use of Primall-EP is required. OPTIMAL SURFACE PREPARATIONS ARE DETAILED BELOW. DEVIATIONS FROM THESE RECOMMENDED PRACTICES WILL VOID ANY WARRANTIES MADE BY LIFELAST, INC. CONCERNING PRODUCT BONDING UNLESS THE Surface Preparation Instructions Page 2
3 DEVIATIONS ARE PRE-APPROVED BY A LIFELAST, INC. TECHNICAL REPRESENTATIVE. CONCRETE PREPARATION INSTRUCTIONS CURE TIME The concrete must be adequately cured before LifeLast coatings can be applied. In order for the moisture content of the concrete to leech out and for the concrete to achieve a proper tensile strength, type I and type II portland cement must cure for 28 days, types III and IV must cure for 7 days. Consult the cure time guides of other types of cementacious materials, or contact LifeLast before coating the surface. If you are not sure of the moisture content of the concrete, new or old, a simple test can be performed to detect the presence of moisture in the concrete. The test, known as ASTM D4263, involves taping an 18 inch square of 4 mil clear plastic to any area where moisture is suspected. After 24 hours, inspect the polyethylene sheet to see if any condensation has formed. If there are beads of water on the plastic or if the concrete is darker or appears damp under the plastic, this indicates the presence of moisture in the concrete. CLEANING AND DECONTAMINATION The surface to be coated should be clean of oils, greases, waxes, dirt, or fats. Use high pressure water blasting or steam cleaning in conjunction with degreasers or cleansing agents. Tri-sodium phosphate mixed at a concentration of 2 pounds to a gallon of water can be used to clean the surface. The surface should be thoroughly flushed with clean water and completely dried. REMOVAL OF LAITANCE All loose materials and laitance must be removed when applying LifeLast s high build high film strength coatings. This promotes optimal surfaces for adhesion. The most common way to achieve this is by abrasive blasting. Abrasive blasting removes all contaminates such as form release agents, curing membranes, and existing coatings. ABRASIVE BLASTING The substrate should be abrasive blasted to provide a surface that is clean and free of any loose materials. Wet blasting is acceptable if the moisture is dried and does not hinder the coating process. Dry blasting techniques are preferred, but care should be taken not to remove any more material than is necessary. Blasting should expose air pockets, bug holes, surface voids, and other surface irregularities. Sharp edges should be rounded by wire brushing or chipping. An anchor pattern similar to coarse sand paper is the type of surface to achieve. Surface Preparation Instructions Page 3
4 The surface preparation methods for creating a profile that are preferred are as follows: (in order of preference) 1. aggregate blasting (not including silica sand) 2. shot blasting 3. abrasive wheel grinding ( 16 grit and larger) 4. roto peening 5. silica sand blasting 6. soft media blasting ACID ETCHING Acid etching is not advised even though it is a procedure that is often performed. REPAIR OF CONCRETE The concrete should be uniform and free from voids, cracks, and irregularities that will cause unsightly appearances on the coating. These areas should be repaired with an approved non-shrink, quick setting cementatious grout. The grout must achieve compressive strengths of hours and hours per ASTM C 109. These areas are to be abrasive blasted and cleaned before coating. EXPANSION JOINTS Expansion joints must be filled with backing rod and or joint compound. The compound should be flush with the concrete surface and the cavity must be dried and power vacuumed to remove all the dust, blasting debris, and residues. After blasting and thoroughly cleaning the joints, a bond-breaking tape, 2 inches wide, should be applied to bridge the gap. Apply the coating according to the recommended methods to the taped areas. Consult LifeLast, Inc. for detailed recommendations. FINAL CLEANING After all substrates are prepared, surfaces adjacent to the work area shall be cleaned of dirt, blasting residue, and other debris to prevent wind-blown contamination of the prepared substrate or freshly applied coatings. Just prior to primer application, surfaces to be coated are to be power vacuumed to remove all dust, dirt, blasting residue, and debris. Transitions into adjacent areas not to be coated shall be neatly taped off or protected. Concrete surfaces may be slightly damp but must be dust-free prior to and during application of the primer. Surface Preparation Instructions Page 4
5 If you have any questions about the above procedures please consult a LifeLast, Inc. technician at the phone number on the bottom of this page. APPLICATION OF PRIMALL-EP The reasons for priming concrete are: 1) priming concrete seals the concrete and reduces pinholing that is a result of the expansion of air in the concrete; 2) priming concrete increases the strength of the concrete and as a result reduces the possibility of future failure; 3) priming concrete aids in the bond of LifeLast urethanes to concrete that is not or may not be completely dry. Please refer to Primall-EP Application Instructions for details on application. APPLICATION OF LIFELAST, INC. URETHANE COATING The application of the LifeLast coatings should be in compliance with the recommendations found in their respective application instruction sheets. Surface Preparation Instructions Page 5
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