SECTION 09800 EPOXY FLOORING SYSTEMS PART 1 GENERAL 1.1 RELATED DOCUMENTS A. Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division 1 Specification Sections, apply to this Section. 1.2 SUMMARY A. Section Includes: 1. Medium Texture Fluid Applied Seamless Epoxy Resin Flooring, Key Mortar SLT 1/8 thickness. 2. Light Texture Fluid Applied High Build Epoxy Coating 40 50 mil DFT Resin Flooring. 3. Smooth, Pigmented Epoxy Floor Coating System 16-18 mils DFT Resin Flooring. 4. Clear Epoxy Floor Coating System. 5. Accessories necessary for complete installation for all systems. B. Related Sections: 1. Cast-in-Place Concrete: Section 03300. a. Concrete sub-floor to be level and to have a steel troweled finish. All concrete slabs shall be either wet cured or cured through the use of moisture-retaining covers. No curing agents or other additives which could prevent bonding shall be used. 2. Decorative Concrete Polished Flooring: Section 09625. a. Surface preparation for Epoxy Stripe Coating system. 1.3 REFERENCE STANDARDS A. American Society for Testing and Materials (ASTM) Publications: 1. C-307 Test Method for Tensile Strength of Chemical-Resistant Mortars. 2. C-501 Test Method for Relative Resistance to Wear Unglazed Ceramic Tile by the Taber Abrader. EPOXY FLOOR SYSTEMS 09800-1
3. C-531 Test Method for Linear Shrinkage and Coefficient of Thermal Expansion of Chemical-Resistant Mortars, Grouts, and Monolithic Surfacing. 4. C-579 Test Methods for Compressive Strength of Chemical- Resistant Mortars and Monolithic Surfaces. 5. C-580 Test Method for Flexural Strength and Modulus of Elasticity of Chemical-Resistant Mortars, Grouts, and Monolithic Surfacing. 6. C-884 Test Method for Thermal Compatibility Between Concrete and an Epoxy Resin Overlay. 7. D-570 Water Absorption of Plastics. 8. D-695 Compression Properties of Rigid Plastic. 9. D-1308 Test Method for Effect of Chemicals on Clear and Pigmented Organic Finishes. B. Military Specifications (Mil. Spec.) 1. MIL D-3 134 F (Impact Resistance) Section 4.7.3. 2. MIL D-3 134 F (Indentation Resistance) Section 4.7.4. 3. MIL D-3234 F (Resistance to Elevated Temperature) Section 4.7.5. C. ACI 301 Specifications for Structural Concrete for Buildings (most recent edition). Committee in Concrete 403 bulletin 59-43, Bond Strength to Concrete. 1.4 SUBMITTALS A. Samples: Submit two 12 inch by 12 inch cured samples of each floor color indicating color combination and non-skid properties. Approved samples will be used during installation for product match. B. Manufacturers Application Instructions: Submit descriptive data and specific recommendations for mixing, application, curing including any precautions of special handling instructions required to comply with the Occupational Safety and Health Act. C. Shop Drawings: Shop Drawings shall be furnished showing installation of cove base and termination details, and details at floor material transitions and where adjoining equipment. Locate and provide detailing for flexible joints required for flooring in area of installation. D. Maintenance Instructions: Submit current copies of the flooring manufacturer's printed recommendations on maintenance methods and products. Submit in accordance with Section 01770 Closeout Procedures. 1.5 QUALITY ASSURANCE EPOXY FLOOR SYSTEMS 09800-2
A. Materials used in the floor surfacing shall be the products of a single manufacturer. B. Installation shall be performed by an applicator with minimum 3 years experience in work of similar nature and scope. Installer must be approved by the manufacturer of the floor surfacing materials. The contractor shall furnish a written statement from the manufacturer that the installer is acceptable. C. Installer to verify locations of all flexible joints required by the provisions of this Section and by the recommendations of the related material manufacturers. 1. Joint locations may or may not be shown in drawings. D. Installer to keep daily log of the date of installation, room number, type, color, and method of application of product being installed. Log must be available for inspection by the owners representative and the Architect upon request. E. Contractor to have proven experience with specified system. F. Mock-up: Prior to starting application of flooring, provide full-scale mock-up to establish acceptable quality, durability, and appearance. Mock-up area must not be less than 50 square feet. 1. Acceptable mock-up to be standard of quality for remaining work. 2. Accepted work may remain in place. Unacceptable work to be removed and replaced until acceptable. 1.6 PROJECT CONDITIONS A. Maintain the ambient room and the floor temperatures at 50 degrees Fahrenheit, or above, for a period extending from 72 hours before, during and after floor installation. Concrete to receive surfacing shall have cured for at least 28 days and shall have been free of water for at least 7 days. B. Advise other trades of fixtures and fittings not to be installed until flooring is cured and protected. 1.7 PROTECTION A. Protect adjacent surfaces not scheduled to receive the flooring by masking, or by other means, to maintain these surfaces free of the flooring material. B. Provide adequate ventilation and fire protection at all mixing and placing operations. Prohibit smoking or use of spark or flame producing devices within 50 feet of any mixing or placing operation. C. Provide polyethylene or rubber gloves or protective creams for all workmen engaged in applying products containing epoxy. 1.8 PRODUCT DELIVERY, STORAGE, AND HANDLING EPOXY FLOOR SYSTEMS 09800-3
A. All materials shall be delivered to project site in original manufacturer's sealed containers including type of material, batch numbers, date of manufacture, and pertinent labels intact and legible. B. Store materials in dry protected area at a temperature between 50 F to 80 F. C. Follow all manufacturer's specific instructions and prudent safety practices for storage and handling. PART 2 - PRODUCTS 2.1 MANUFACTURERS A. Key Resin Company. Contact: Fred Ramsey (757) 253-7577, (804) 512-4429. 2.2 CERTIFIED INSTALLER/APPLICATOR A. The applicators for this product is proprietary. No other installers will be allowed. 1. FlorLine Inc. Shane Reynolds (330) 830-3380 2. QuestMark, division of CentiMark. Ron Pritt (717) 965-9340, (484) 488-3048, or ron.pritt@centimark.com. 2.3 MATERIALS A. Medium Texture Fluid Applied Seamless Epoxy Resin Flooring shall be Key Mortar SLT 1/8 Textured Self Leveling Flooring System, sealed with Chemical and Stain Resistant Polyurethane Sealer, Key #470 Polyaspartic Topcoat. 1. Prime Coat: Two component penetrating damp-proof epoxy: Key #502 Primer/Low Modulus Binder. 2. Aggregates: a. Blended self-leveling slurry filler: Key Self-Leveling Filler. b. Key CEC 1000 Broadcast Aggregate. 3. Matrix: Matrix-epoxy/aggregate composition using 100% solids epoxy binder: Key #511 Epoxy Binder (pigmented). 4. High solids seal coat: a. Colored two component, 100% solids epoxy: Key #520 100% Solids Epoxy Coating b. Colored two component, chemically cured polyaspartic: Key #470 Polyaspartic Topcoat. 5. Flexible epoxy joint filler: Key #780 Joint Filler to match color of floor topping. EPOXY FLOOR SYSTEMS 09800-4
6. Elastomeric, crack-bridging membrane: Key #580 Flexible Epoxy B. Light Texture Fluid Applied High Build Epoxy Coating Resin Flooring 40 50 mils DFT. 1. Severe and Moderate Environments (Gloss Finish): One finish coat over a primer coat of epoxy with a broadcast aggregate for non-slip surface and grout coat of pigmented epoxy. a. Primer: Two-part 100 % Solids Epoxy Primer. Primer coat to be applied over properly prepared concrete substrate at 10.0 mils WFT. While material is wet broadcast 30 mesh washed silica sand at approximately 20 lb. per 100 sq. ft. (to excess). 1) Key Resin Company: Key Resin # 502 Primer/Low Modulus Binder Clear. 2) Key Resin Company: Key Resin 30 Mesh Broadcast Aggregate. b. Intermediate Coat: Two-part 100% Solids Epoxy Binder. Key Resin Company: Key # 520 Epoxy Coating Carmax Gray. After primer has cured sweep excess aggregate from floor and apply intermediate coat at 10 mils WFT to lock in aggregate. c. Finish Coats: Two-part 100% Solids Epoxy Binder. Key Resin Company: Key Resin # 520 Epoxy Coating Carmax Gray. Apply finish coat at 10 mils WFT. C. Epoxy Stripe Coating 1. Stripes located at Decorative Concrete Polished Flooring in Service and FQC as indicated on drawings. a. Primer: Key Resin # 502 Epoxy Primer (pigmented white will help top coat cover better but not required) @ 200 sq. ft. per gallon (8 mils DFT). b. Finish Coat: Key Resin # 470 Polyaspartic Carmax Yellow @ 160 sq. ft. per gallon (10 mils DFT). D. Smooth, Pigmented Epoxy Floor Coating System 16-18 mils DFT 1. Severe and Moderate Environment (Gloss Finish): One coat over a primer coat. a. Primer: Two-part 100% Solids Epoxy Primer. Primer coat to be applied over properly prepared concrete substrate at 8.0 to 10.0 mils WFT. While material is wet broadcast 30 mesh washed silica sand at approximately 20 lb. per 100 sq. ft. (to excess). 1) Key Resin Company: Key Resin # 502 Primer/Low Modulus Binder Clear. b. Finish Coat: Two-part 100% Solids Epoxy Coating (Carmax Gray) applied at 8.0 to 10.0 mils WFT. EPOXY FLOOR SYSTEMS 09800-5
1) Key Resin Company: Key Resin # 520 Epoxy Coating Carmax Gray at 8.0 to 10.0 mils WFT. E. Clear Epoxy Floor Coating System 1. Paint Booth Flooring (Gloss Finish): One coat over a primer coat. a. Primer: Two-part 100% Solids Epoxy Primer. Primer coat to be applied over properly prepared concrete substrate at 5.0 to 8.0 mils. WFT. 1) Key Resin Company: Key Resin # 502 Primer/Low Modulus Binder Clear. b. Finish Coat: Two-part 100% Solids Epoxy Coating Clear applied at 5.0 to 8.0 mils WFT. 1) Key Resin Company: Key Resin # 502 Primer/low Modulus Binder Clear. 2.4 FINISHES Color and texture as indicated on drawings. PART 3 - EXECUTION 3.1 PREPARATION A. Obtain Architect's approval of mock-up before installing flooring. B. Prior to installation of structural floor slab, advise General Contractor, in writing, of all requirements of concrete substrate regarding finish, level tolerance, and curing. C. Locate all flexible joints required. D. Preparation of Surface: 1. After concrete curing period (28 days minimum) has elapsed, inspect surfaces to receive flooring and verify that condition is smooth and free from conditions that will adversely affect execution, permanence, or quality of work. Remove all projections, all debris detrimental to flooring system, and dirt, oil contaminates, grease, and surface coatings affecting bond. 2. Notify Architect in writing prior to commencing work of any conditions deemed unsatisfactory for the installation; installation of flooring materials is understood as acceptance of the substrate as satisfactory. EPOXY FLOOR SYSTEMS 09800-6
3. Verify that moisture content is within range acceptable to flooring material manufacturer using calcium chloride test per ASTM F1869 and/or relative humidity probe test per ASTM F2170. 4. Prepare surface as required by manufacturer's printed instructions. Preferred surface preparation is steel shot blasting or similar mechanical method. 5. Air Drying: After completion of cleaning, allow concrete surface to air dry thoroughly prior to application of the floor surfacing. Blowers or oil free compressed air may be used. Do not use flame-drying methods. Prior to application of surfacing, the concrete surface shall be tested for excessive moisture vapor transmission in at least two locations. Place rubber mats at each location with smooth side against concrete. Polyethylene with all edges taped may be used in lieu of mats. After 16-24 hours, remove mat or sheeting and examine the floor surface for moisture accumulation. If tests indicate an accumulation of moisture at either location, additional air-drying shall be undertaken until such time as additional tests show no moisture accumulation. 6. Treat cracks in concrete using manufacturer's recommended practice. Rout out crack and joints, and fill with semi-flexible epoxy; coat with flexible membrane in accordance with manufacturer's recommendation to prevent cracking through flooring system. 7. Remove plastic void cap at the top of the expansion joint material placed at the perimeter of the concrete slabs. Clean joint of all foreign material. 8. Verify that surface preparation for Epoxy Stripe Coating meets manufacturers requirements. 3.2 INSTALLATION A. Install all floor materials in strict conformance with manufacturer's instructions. B. Install a screed line or termination strip at all color transitions except at stripes where a masked edge topcoat of a different color shall be installed. C. Elastomeric membrane, if required, at concrete slab applications and where indicated. Install in single or multiple coats to a minimum dry film thickness of 25 mils. D. Once self-leveling broadcast epoxy materials have cured remove excess broadcast sand from floor surface. E. Match finished work to approved samples, uniform in thickness, sheen, color, patterns and texture, and free from defects detrimental to appearance. F. Install flexible joint filler at all perimeter expansion joints where concrete slab abuts vertical wall assembly. Color of filler to match floor system. G. Install flexible epoxy joint sealant in all saw cut and cold joints. H. Apply temporary protection until floor is fully cured. EPOXY FLOOR SYSTEMS 09800-7
3.3 INSPECTION A. Touch up and repair all work that is not acceptable to Architect and request final acceptance. 3.4 CLEANING AND PROTECTION A. Remove coating spatters from glass, plumbing fixtures, and adjoining surfaces. B. Repair any damage to coating or surfaces caused by cleaning operation start. C. Remove debris from job site and leave storage area clean. D. At Presentation Lanes protect finished surfaces from damage for remainder of construction period until project is turned over to Owner. END OF SECTION 09800 EPOXY FLOOR SYSTEMS 09800-8