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Find the information you need for a specific product or category, so you can make the right product choice for your project. Epoxy Coating Guide for Concrete. Design Guide Epoxy Coatings. High performance epoxy coating materials are used to protect concrete and steel from chemical and mechanical attack in interior, exterior and marine environments. Epoxy coating systems consist of two or more components which, when blended and applied as a film, react chemically to form a protective film of high integrity, excellent adhesion, toughness and impact resistance. These coatings are applied in films ranging in thickness from several to over 1. Coatings provide a barrier to elements which otherwise may attack the substrate. The chemical formulation of the coating material will determine its resistance to specific chemicals while resistance to mechanical loads, such as abrasion and impact, is a function of the physical properties and the thickness of the coating film. Solvent born coatings generally have a long pot life and are thinner and therefore, easier to apply. The dry film thickness or the film remaining after solvent evaporation is proportional to the solids content of the coating material and the applied or wet film thickness. In order to avoid sag or runs and to allow proper solvent evaporation, solvent borne coatings are applied as thin films. Application at low temperature or in thick films may cause solvent entrapment, giving rise to blisters or peeling. Solvent born coatings are particularly useful as primers, sealers, surface penetrants or where high film thickness is not required. In recent years, epoxy coatings have been developed which use water as the vehicle. Such products contain the coating materials as emulsions or dispersions, which upon application and evaporation of the water coalesce to form the protective film. Solventless 1. 00 solids coatings contain no volatile ingredients, therefore, the final thickness of the cured coating is the same as the applied thickness. Advantages of solventless over solvent borne coating materials are. Fewer coats are required to achieve a desired film thickness. Low temperature cure can be achieved. Kodak Easyshare Software For Windows 7. Air ventilation requirements are reduced during application and curing. Air pollution and fire risks are minimized. VOC compliance. When used on floors and decks, epoxy coatings can be skid proofed by imbedding grit into the surface layer or reinforced by incorporating glass cloth. Trowelable coating materials of nonsag or mastic consistency are used for applications of thick layers on vertical and overhead surfaces. Some high performance epoxy coatings for steel and concrete surfaces may chalk and discolor upon exposure to direct sunlight that causes their finish to turn dull. These features should be considered in exterior architectural coating applications. Protecting Against Highly Aggressive Chemicals. Most applications requiring a high degree of chemical resistance are found in the manufacturing and chemical processing industries. Properly formulated and applied coating materials can stop the action of chemicals that rapidly deteriorate concrete and steel. Applications requiring high chemical resistance include. Refineries, electroplating plants, chemical processing plants, battery handling rooms. Food processing plants, meat packing areas. High nuclear radiation exposure areas. Manufacturing plants, particularly where cutting oils are used. Protecting Against Moderately Aggressive Chemicals. Epoxy coatings protect concrete and steel which are exposed to mild chemical attack from sources such as acid mist, organic acids and water containing corrosive chemicals. Concrete surfaces are often porous, subject to bacterial growth and difficult to clean. The glossy, tile like, impervious natures of these coatings provide ideal protection in the following areas. Institutional and commercial kitchens and laundries. Sewage and water treatment tanks and digesters. Breweries and winery facilities. Protection of concrete columns, piers and abutments from intrusion of de icing salts. Protection of concrete and steel in marine structures above the splash zone. Protection of concrete against erosion from high velocity water. Providing Skid Resistance on Traffic Surfaces. The skid resistance of concrete, steel and asphalt surfaces can be improved by the application of a skid resistant coating. This consists of selected aggregate imbedded into the coating. The aggregate dramatically increases the coefficient of friction of the otherwise smooth coating. Areas that receive heavy wear due to high traffic speed and volume require a surface texture that will not be worn away or polished smooth. Skid resistant coatings are used to surface. Industrial floors Parking garage decks and ramps Loading docks Concrete bridge decks Toll plazas. Coating Marine Structures. Epoxy coatings are used to protect concrete and steel marine structures as formulations are available to adhere to wet substrates. Marine coating use can be divided into two areas, splash zone application and underwater application. Both applications require the ability of the coating material to be workable, adhere and cure underwater in the splash zone the material must resist wave action during application and after cure. Typical applications for the protection of marine structures include. Coating piles, piers, sea walls and abutments in the splash zone. Coating water tanks, fish ladders, dams, and outfall structures. Coating piles, piers, seawalls and abutments underwater. Design Considerations. Effect of Temperature. Application Temperature The temperature at the time of application will affect the handling characteristics of the material, the evaporation rate of the solvent from the film and the curing characteristics of the coating. In an exterior application, the optimum timing for coating placement is during a period of declining surface temperature to minimize the potential for blistering caused by water vapor transmission see 1. Service Temperature Most physical properties of epoxies are affected by temperature. It is important to identify the service temperature range for a proposed application in order that the performance characteristics of a candidate product can be evaluated. Moisture. 1. 2. 1. Surface Moisture Although certain materials will adhere to a moist surface, superior adhesion is achieved in dry conditions. Rising Moisture Water vapor will travel through a porous substance such as concrete from an area of high humidity to one of low humidity. When the flow of this moisture is interrupted by an impervious layer such as a epoxy, it may cause blistering of uncured material. Moisture that collects beneath a cured overlay can also cause spalling should freezing occur. This condition is particularly prevalent with slabs on grade with no moisture barrier between the soil and slab. Rising moisture can be detected by taping a 3 foot square sheet of polyethylene to the floor. After 2. 4 hours, if the concrete under the sheet appears dark or condensation forms on the underside of the sheet, a rising moisture condition exists and corrective measures should be evaluated prior to coating. The flooring industry has established a minimum standard of 3 pounds or less of water transmission per thousand square feet per 2. If moisture is suspected, several test kits should be placed at random intervals around the floor slab. Condensing Moisture When the temperature of the slab is at or below the dew point of the atmosphere, moisture will condense on it.