Classic Concrete Finish Panel. Owner s Manual

Transcription

1 Classic Concrete Finish Panel Owner s Manual

2 Table of Contents Classic Concrete Care and Maintenance... 3 Cleaning Procedures... 3 Sealing the Classic Concrete Panels... 4 Owner s Tool List... 6 Panel Removal and Replacement... 6 General Guidelines and Safeguards... 6 Removing Panels... 6 Replacing Panels... 7 Stringer Removal and Replacement... 7 Stringer Removal and Replacement Guidelines... 7 Floor Panel Load Capacities... 7 Protecting the Floor from Rolling Loads... 7 Verifying Equipment Loads are within the Capacity of the Floor... 7 Classic Concrete Panels... 8 Service Load Capacity: 1,250 lbs Move-in Rolling Load Capacity: 1,000 lbs Daily or Frequent Rolling Load Capacity: 800 lbs Protecting the Floor... 8 Protecting the Floor from Wheel Marks during Move-in... 8 Protecting the Floor from Day-to-Day Use... 8 General Rolling Load Safeguards... 8 Cutting Panels... 9 Cutting Safety... 9 Cutting Tools and Equipment... 9 Best Practices for Panel Cutting Making Straight Cuts Making Curved Cuts Factory-supplied Cutouts Making Rectangular Cutouts on Site Making Round Cutouts on Site Page 2

3 Classic Concrete Care and Maintenance Tate s Concrete finishes are designed for years of service with minimum maintenance. Adherence to the guidelines below allows maximum life to be obtained from this tile. The panels should not be exposed to construction traffic and must be protected just as any finished floor coverings. Do: 1. Provide protection from sand and chemicals tracked in on shoes by providing walk- off mats at entrances. 2. Rotate panels in high-use areas to areas of low traffic to spread years of wear over the entire system. 3. Use felt furniture glides designed for hard surface finishes. Metal or plastic glides designed for carpet should not be used on Classic Concrete flooring. 4. Use chair mats under casters. Casters should be soft rubber and designed for hard surface finishes 5. Use felt floor protectors under equipment, appliances or heavy point loads. 6. Keep the floor clean by light damp-mopping with a mild multi-purpose floor cleaner or mild detergent. Don't: 1. Flood the floor or use anything other than a damp mop. 2. Use strong abrasives, steel wool, nylon pads or scrapers to remove stains. 3. Drag or slide furniture or equipment across the floor without the use of glides. Cleaning Procedures When light soiling is widespread and spot cleaning is impractical, use this damp-mopping procedure: Damp Mopping Procedure: 1. Sweep or vacuum your floor thoroughly. 2. Damp-mop with warm water and mild multipurpose floor cleaner. 3. Dip a sponge mop into a bucket of warm water, wring it out well, and push the sponge across the floor, pressing hard enough to loosen the surface dirt. 4. Damp-mop a small area at a time, wringing the sponge out frequently to ensure the dirt is lifted and not just redistributed. 5. When damp-mopping a large floor, change the water several times so the dirt doesn t get redeposited on the floor. 6. Rinsing is the most important step. Detergent directions often state rinsing is not necessary. While this is true on some surfaces, any detergent film left on a floor will hold tracked-in dirt. 7. Ideally, use one sponge mop and bucket to clean the floor and another mop and bucket solely for rinsing. Page 3

4 Cleaning the Floor If damp mopping is unable to clean the surface, more aggressive means to clean the surface will be necessary. In this case, we would recommend cleaning with an auto floor scrubber with a water extractor; however, it is important that water is not excessive enough to seep through the panel seams. A mild detergent may be used after ensuring the detergent does not discolor the finish by testing it on a scrap panel. Any brushes or pads that are used to clean the panels are to be only soft nylon bristle to ensure the panels finish is not scratched or changed. Test in an inconspicuous area to ensure the panel s aesthetic has not changed before proceeding. After cleaning the floor, give it a final rinse with clear water to remove any remaining dirt and residue. Example of Auto Floor Scrubber The floor must be given ample amount of time to dry undisturbed before moving onto the next process. It is absolutely critical that the Concrete panels are clean, with all loose debris removed and dry before applying any sealant. Sealing the Classic Concrete Panels It is absolutely critical that the Concrete panels are clean, with all loose debris removed and dry before applying any sealant. Tate s Classic Concrete panels are not sealed in the factory. We do however recommend that a sealer be field applied to protect against staining since the product is porous. There are many choices of sealers in the market - from penetrating sealers (silanes or siloxanes) to topical water or solvent based acrylics, to a host of hybrid sealers tailored to provide enhanced stain resistance such as fluropolymer additives. These sealers come in a variety of gloss levels and tints and will have various maintenance schedules and protocols. You will want to stay away from viscous sealers like urethanes or epoxies as they tend to fill in the seams of the panels and adversely affect the accessibility of the system. Although there are many good sealers on the market, we liked Prosoco Consolideck Concrete Protector WB product. This product is easy to apply, has excellent stain resistance, and maintains the natural look of the product. A summary of the sealer is provided below along with a link to the manufacture s site and Tate s test report. Page 4

5 Consolideck Concrete Protector WB Sealer Type Application Method Coverage Coats Finish Stain Resistance Slip Coefficient Recoat Procedure Link to Site Test Report Penetrating water based fluorochemical urethane Low Pressure pump sprayer 1 gallon will cover approx. 250 ft 2 in one coat Single saturating application. 2nd application if needed. Clear matte finish -retains the natural look of the product. Excellent 0.65 (per ANSI A137.1) Sealer can be reapplied at any time to clean and dry surface Concrete Protector WB Tate s Test Report Sealing with Non-Tate Approved Sealers or Choosing Not To Seal As mentioned above, there are many other sealers on the market and although we recommend the above sealer, it is up to the end user to decide what sealer they prefer to use. You do need to keep in mind several things when choosing the sealer. If you choose a topical sealer, you should have the opportunity to strip it and reapply the same or a different sealer in the future, depending on the specific sealer. If you choose a penetrating sealer, you will be limited to what you can apply in the future, if anything. You will need to follow the specific manufacturer s guidelines for application and re-application including compatible cleaning products, additional sealers or stains. It is important that you understand the properties of the sealer you select. The manufacturer s guidelines should provide you with information on stain resistance, chemical resistance and slip resistance. You should also remember that sealers may change the appearance of the panel. You should test a small area in an inconspicuous place prior to sealing the entire floor to ensure it is the look you want. This also applies if you choose to not seal the floor. Without a sealer the floor will be subject to staining from common liquids like coffee and soda, and it will make ground in dirt much more difficult to remove. The regular maintenance listed above will more than likely need to be done more frequently on an unsealed floor. Regardless of the sealer, if any, you choose you must not do the following: 1. Flood the floor or use anything other than a damp mop. 2. Use strong abrasives, steel wool, nylon pads or scrapers to remove stains. 3. Drag or slide furniture or equipment across the floor. Page 5

6 Owner s Tool List 1. Tate s double suction cup lifter, Price List part number Battery powered torque limiting screw gun, DeWalt, Hitachi, or Mikita 3. Replacement tips for the screw gun, #3 Phillips 4. #3 Phillips screw driver Panel Removal and Replacement General Guidelines and Safeguards 1. To keep the floor straight and square, it is best to remove panels only where immediate access is required and reinstall panels as your work progresses. When removing several panels at a time, no more than six adjacent panels should be removed at once. 2. Do not drag or slide the panel across the floor when putting a panel to the side. 3. Do not attempt to carry a panel by the lifter the suction could release and allow the panel to fall from your hand. 4. When removing and reinstalling cut panels at the floor perimeter and around columns, reinstall each cut panel from where it was removed. Perimeter panels are precisely cut for each location. Interchanging perimeter panels that may have been cut to different sizes can cause floors to become out-of-square or cause sections of the floor to become tight or loose. Removing Panels 1. To remove the first panel from the floor, kneel in front of the panel you want to remove. 2. Attach the double suction cup lifter near the edge of the panel and lift the end facing you a couple of inches. 3. With the opposite end of the panel resting on the stringers, tilt the panel up by hand (not using the lifter) and stand up. 4. Grasp both sides of the panel and lift the panel from the floor. Lay the panel to the side without dragging it across the floor. 5. Once the first panel is out of the floor, nearby panels can be removed either by using the lifter or by reaching under the panels and pushing upward. Page 6

7 Replacing Panels 1. When more than one panel in a row is removed from the floor, it is possible to replace all but the last panel without using the suction cup lifter provided there is sufficient working room under the floor to position the panels into place. The lifter can also be used to position the panels into place. 2. The last panel must be positioned on the stringers using the lifter. Attach the lifter near the center of the panel. Lower the panel into the opening by hand and use the lifter to slightly lift and move the panel into place. 3. Be careful not to slide panels across the floor when reinstalling them as doing so can scratch the floor surface. Stringer Removal and Replacement Stringer Removal and Replacement Guidelines 1. When it is necessary to remove stringers, it is best to remove only a couple of stringers at a time where immediate access is required and reinstall them as your work progresses to keep the floor straight and square. 2. Use a torque limiting screw gun with #3 Phillips bit set to 30-inch pounds. 3. Do no over-tighten the screws because doing so can cause the stringers to spread out at bottom. 4. Do not under-torque the screws because doing so can cause the system to become loose. Floor Panel Load Capacities Protecting the Floor from Rolling Loads Verifying Equipment Loads are within the Capacity of the Floor Rolling equipment and vehicles such as, dollies, pallet jacks, and lifts that exceed the floor s capacity can damage the floor. Check the equipment manufacturer s specifications to verify that your payload combined with the load of the equipment you want to use will not exceed the rolling load capacities indicated on page 8. Have a Question? Call Tate s Technical Hotline or visit our website at Page 7

8 Classic Concrete Panels Service Load Capacity: 1,250 lbs. A Classic Concrete panel will support a load of up to 1,250 lbs. load concentrated on a single leg or foot or on any larger area. Alternatively, a panel will support multiple concentrated loads simultaneously provided the total load does not exceed 1,250 lbs. Move-in Rolling Load Capacity: 1,000 lbs. For equipment and furniture move-ins, loads of up to 1,000 lbs. can be rolled across each panel at one time. The load can be imposed through a single wheel or two wheels simultaneously provided the total load does not exceed 1,000 lbs. Daily or Frequent Rolling Load Capacity: 800 lbs. For routine rolling load traffic, loads of up to 800 lbs. can be rolled across each panel at one time. The load can be imposed through a single wheel or two wheels simultaneously provided the total load does not exceed 800 lbs. Protecting the Floor Protecting the Floor from Wheel Marks during Move-in To prevent wheel marks or scuffs from forming on the floor during move-in, use non-marking tread wheels, or cover the floor in the load path with Masonite or plywood. To Use Masonite or plywood: 1. Tape plastic sheets to one another and to the floor surface. 2. Lay 3 16 or ¼ thick sheets of Masonite or ½ thick sheets of plywood on top of the plastic and tape together with duct tape. Protecting the Floor from Day-to-Day Use To prevent scuffs, scratches, and uneven wear, use felt furniture glides and soft rubber nonscuff casters designed to be used on hard surface finishes. Metal or hard plastic glides, feet and casters for carpet should not be used on Classic Concrete flooring. Avoid dragging furniture or heavy objects across the floor without protecting the finish. Use of walk-off mats at entrances and rotating panels from heavy traffic areas will help extend the life of the sealant and panel finishes. Follow the care and maintenance instructions for proper cleaning and daily up-keep. General Rolling Load Safeguards 1. Make sure all floor panels in and around the load path are in place to prevent the floor from shifting. 2. Do not allow heavily loaded objects to drop to the floor when stepping down from a higher level. Page 8

9 Cutting Panels Cutting Safety All governing organizational safety standards must be followed and practiced at all times. Proper Personal protection equipment should be worn during the cutting process. Tate recommends the following personal protection equipment be utilized; however, this is not an allencompassing list for every situation. Personal Protection Equipment Safety glasses Ear plugs / muffs Steel toe safety boots with aggressive slip resistant tread NIOSH approved face mask Snug, flexible safety gloves Equipment Needs All cutting equipment guards and shields be in place Ground Fault Interrupter System Cutting Tools and Equipment 1. Mobile Applications Model MA-615 Band Saw a. Lenox Master-Grit Carbide grit band saw blade ¾ x.035 Coarse gulleted grit b. Lenox Master-Grit Carbide grit band saw blade ½ x.025 Medium continuous grit c. Lenox CM ¾ x.035 x 6 raker with carbide teeth 2. IMER Combicut 250 VA 10inch Circular Tile & Stone Saw a. Cured Concrete Wet Diamond Blade 3. Skilsaw 7 IN. MEDUSAW Worm Drive for Concrete (with water feed assembly) a. DeWalt DW3521 Abrasive Blade 4. DeWalt 331K Hand-Held Jig Saw (or similar models) a. Bosch Diamond Grit Jigsaw Blade Page 9

10 5. Hilti DD 110 W/D / Hilti DD 160 Core bore machines a. Diamond blade 6. Groo-V Tip Multi-Purpose Masonry Bits for holes from inch. Best Practices for Panel Cutting Locate the panel cutting operation in a place that will prevent or minimize dust generation in installation areas. When wet cutting, cut panels should be washed off to avoid cutting debris from sticking to and drying on the surface of the panel. Allow panels to dry before stacking or installing them in the floor. When dry cutting, cut panels should be cleaned with wet white rags before installing them in the floor. Colored rags may bleed and stain the panel. Making Straight Cuts Straight cuts are best made using a wet circular table saw or hand-held concrete (worm gear) circular saw made for wet cutting. Wet cutting creates straighter, cleaner cuts with less dust generation. When wet cutting, layout lines should be made with a permanent marker which marks on Concrete or by scoring the surface of the Concrete with a 1/16-1/8 deep cut prior to making the full-depth cut. (The scoring cut should not produce enough mud to obscure your drawn line.) Perimeter panels: Perimeter panels should be measured and cut to fit at each location taking into consideration that walls may be wavy or out of square. Measurements should be made twice to ensure that panels are cut tight to the wall or curb. When making complex cuts we recommend the use of cardboard panel templates before cutting actual panels. Tip: The edges of perimeter panels cut to walls, columns and curbs can be beveled from the top to make panel removal and installation easier. A 5 degree bevel cut is adequate. Making Curved Cuts Curved cuts can be made using a band saw with carbide grit or carbide teeth blade. Factory-supplied Cutouts Tate provides factory cutouts precisely made by water jet cutting and can provide panels with various sizes and shapes of interior cut. We recommend the use of water jet cutting when interior cutouts must be made outside of the factory. Making Rectangular Cutouts on Site Interior cuts can be made using a hand-held circular saw with water feed assembly and cured concrete diamond blade. Do not cut beyond the corners of the cutout with the circular saw finish the cut through the full depth of the panel using a jig saw with a diamond-grit blade. Do not locate rectangular cutouts closer than 4.5 from any panel edge. Page 10

11 Depending on the size and location of the cutout, extra pedestals may be needed for panel reinforcement near the cutout. For cutouts larger than 110 square inches, consult Tate s Technical Services department for reinforcement recommendations. Making Round Cutouts on Site Round cutouts are best made using a hand-held core drill (made for wet and dry operation) with a diamond core bit. This is the fastest and most economical method which produces the highest quality of cut. We recommend wet cutting for holes larger than 3 inches in diameter. Cutouts 3 inches or smaller can be cut dry when a dust management system is incorporated into the drill machine. Round cutouts can also be made using a jigsaw with a diamond-grit blade. Create a pilot hole with a non-percussive drill and masonry drill bit. Do not use a hammer drill to make the pilot hole because it can cause breakout of the Concrete surface. Do not locate round cutouts closer than 3 from any panel edge. Page 11

12 Corporate Headquarters: 7510 Montevideo Road, Jessup, MD Tate Hotline: Tel: Fax: Production Facilities: 7510 Montevideo Road, Jessup, MD Springvale Road, Red Lion, PA Tel: Fax: Canadian Sales & Support Office: 880 Equestrian Court, Oakville, ON L6L 6L7 Canada Tate Hotline: Tel: Fax: Asia Sales & Support Office: 19 Cecil Street #05-15, 5th Floor, The Quadrant Singapore Tel: Central and South American Sales & Support: Tel: European Sales & Support: B16 Ballymount Corporate Park, Ballymount Avenue, Ballymount, Dublin 12, Ireland Tel: +353 (0) Middle East Sales & Support: Jebel Ali-Lahbab Road (E 77 Road) Dubai Investment Park United Arab Emirates Tel: Australian Sales & Support Office: 28 Biloela Street, Villawood NSW 2163 Tel: Fax: Page 12