Commercial and Industrial Flooring Systems

PREP
APPLICATION
&
TROUBLESHOOTING
GUIDE
 Commercial and Industrial Flooring Systems

Benjamin Moore® Corotech® High-Performance Flooring Systems are designed for CONTENTS:
application by professionals in commercial and industrial environments, as well as select
residential spaces. These products provide enhanced appearance and lasting 2
DIAGNOSTICS
protection for cleaner, safer, brighter and more productive environments.
3
This Prep, Application & Troubleshooting Guide will help you diagnose the condition SURFACE PREPARATION
of the floor, prepare it properly, and correctly apply a Corotech floor coating. Your
Benjamin Moore retailer or specialty coatings representative can assist you further or 4
APPLICATION
guide you through unique project considerations, including the most important part of
the process: Thorough and effective preparation. 5
TROUBLESHOOTING
To learn more about the right Corotech product to choose for a particular flooring need,
talk to your Corotech retailer or read the Corotech Flooring Systems Product Guide. The
entire portfolio of Corotech high-performance primers, enamels, epoxies, urethanes and
more can be found at benjaminmoore.ca.

©2016 Benjamin Moore & Co., Limited. Benjamin Moore and the triangle “M” symbol are registered
trademarks of Benjamin Moore & Co., Limited. All other marks are the property of their respective owner.
1
DIAGNOSTICS

TEST FOR SEALERS Plastic Sheet: Tape to the concrete from the preparation of the
AND CURING COMPOUNDS an 18 x18-inch sheet of clear concrete or from water used
polyethylene plastic, approximately later to clean or wash off various
Clear sealers based on alkyd, epoxy, 4 mils thick, and allow it to remain residues.
urethane, silicone and acrylic resins in place for at least 16 hours.
are used to control laitance and Be sure to seal all edges (ASTM TEST pH OF THE CONCRETE
dusting on concrete. Curing D4263-83). If moisture collects
compounds based on waxes, epoxies, under the plastic in any amount, The pH level of the concrete
and acrylics are incorporated into then the Calcium Chloride test should be evaluated on a pH scale.
the wet concrete when poured below should be performed, Concrete is usually alkaline (also
to control the rate of moisture which will give a measurable called basic). High pH levels can
loss during initial curing. The type result, before a coating is applied. cause saponification (a chemical
of sealer or curing compound reaction that creates a soap-like
present will influence the mode Calcium Chloride: To measure the substance when the concrete
of preparation. Test sample areas rate of moisture-vapour emission is coated), which will lead to
of the floor by placing a few drops from the concrete, place a delamination of the coating. Cured
of diluted muriatic acid on the measured amount of anhydrous concrete has a pH level
concrete. If the acid bubbles, the calcium chloride in a dish inside between 8 and 10 and can be
concrete is free of sealers or curing a transparent plastic cover that is tested with pH paper strips.
compounds. If it does not bubble, sealed to the floor. Pre-measured
a sealer or curing compound is kits with instructions for the test Environmental Conditions
present and must be removed are often sold by Corotech retailers
Thorough and effective
before application of a coating. and big box home improvement Air and surface temperature, direct
preparation is the key to retailers. After 60 to 72 hours, heat/sunlight, relative humidity
a successful floor job, and TEST FOR OIL AND GREASE weigh the calcium chloride and and dew point are important
the first step in preparation perform calculations to determine factors to take into consideration
is testing and diagnosing Contamination from oil and grease the amount of water absorbed before applying a coating to
prevents strong penetration and (ASTM F1869-11). concrete.
the condition of the current bonding of the coating system • High humidity slows down the
floor and the project to the concrete. To test for the The moisture-vapour emission rate drying process. Note: Warm
environment: presence of oil/grease, sprinkle is calculated in pounds of water air holds more moisture. For
water on the concrete surface in per 1,000 square feet per a 24-hour example, air at a temperature
several locations, including areas of period. Rates below 3-5 pounds of 90° F and 50% relative humidity
• Ensure the concrete are generally recommended to
activity and traffic patterns. If the holds significantly more
itself is in sound water beads, these contaminants avoid possible coating failure due moisture than air at 70° F and
condition and fully are present and must be removed. to moisture. Flooring applicators 50% relative humidity.
cured – make repairs If the water spreads out and is should be sure to advise facility • The dew point should be
if necessary. absorbed, they are not present. manager/owner of moisture-vapour monitored. This is the
emission test results. temperature at which moisture
TEST FOR MOISTURE vapour will condense on a
• Analyze for the IN THE CONCRETE Moisture Meter: Use a moisture surface. During the application
presence of sealers, meter to determine a percent of the system, dew formation
curing compounds, All concrete contains some moisture. reading of moisture present in the can cause curing and
Excess amounts of moisture often concrete. Less than 3-5% is appearance problems and
oils, grease and other signal that a coating applied to generally recommended before should be avoided.
contaminants. that concrete will fail over time. proceeding with application of a • Direct sunlight and high air flow
Testing for moisture allows the coating. Moisture is often present (convection) can affect curing.
• Measure the moisture flooring applicator to proceed with
content of the concrete. confidence or to recommend to
the facility manager or owner that
TEST pH OF CONCRETE
the moisture be mitigated before a
• Test the level of alkalinity coating is applied. SAFE TO COAT
or pH of the concrete.
There are three common tests.
Using all three will ensure the 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14
• Observe environmental best possible estimate of moisture Acidic Neutral Alkaline
conditions impacting content; the bare minimum should
pH SCALE
application. be the plastic sheet test.
2
SURFACE PREPARATION

CLEANING AND DEGREASING effective means of mechanical small grooves (approx.1/4-inch

surface preparation. deep) made around drains,
All traces of oil and grease and doors and transitions in the floor.
other contaminants must be Shot Blasting Although not used to prepare
removed from a concrete floor an entire floor, these key cuts
before acid etching, grinding or The preferred method of mechanical can serve as anchor points for an
shot blasting. Grinding and shot preparation that strips thin existing epoxy system, limit sections of
blasting without cleaning will only coatings, cleans and profiles failure, and reduce undercutting
push contamination deeper into simultaneously. It is suitable for by chemicals.
the porous concrete surface, which large and small areas; delivers high
will affect proper bonding of the production rates; is dust free, dry Patching and Repairing
coating system. Use Corotech V600 and cost-effective. Excess shot
Oil and Grease emulsifier to clean must be swept-up after blasting. Settling cracks should be repaired
the floor thoroughly. Stubborn or after preparation of the entire
heavy residue areas may require Scarifying floor and after the primer/sealer is
repeated applications. applied, but before finish coat-
Method uses metal or carbide ing. Expansion joints should be
CREATING A PROFILE disks that rotate at high speeds. repaired and filled after the entire
Levels uneven floors and edges coating system is in place. When
Concrete profile standards have of concrete. Removes adhesives patching, apply the sealer to the
been established by the ICRI (Inter- and thick film coatings. Dusty crevice to be repaired before
Once the condition of the national Concrete Repair Institute) and labour intensive. Leaves very applying epoxy patch. This will
and range from CSP 1 to CSP 9 rough profile only fit for high-build enhance the bond strength of the
floor and one environment coatings.
(concrete surface profile). Regular patch. Apply epoxy/aggregate
are properly diagnosed and floor coatings including epoxies mixture immediately after mixing,
any mitigation steps taken, require a surface profile of CSP 2 Diamond Grinding spread with trowel, grind off
the next step is surface or 3; pictorial or model standards excess.
are available and can be achieved Diamond bits are used to grind the
preparation. The surface of a surface. Leaves a very smooth profile;
with various mechanical methods. APPLYING A HIGH-PERFORMANCE
concrete floor is prepared to Acid etching can also be used as a ideal for thin film system applications. COATING OVER AN EXISTING
increase the porosity, profile secondary option. Low dust levels. Removes existing COATING
epoxies and urethanes. Slower than
and surface area so that the
Acid Etching other methods. Applying a Corotech high-perfor-
new coating can penetrate,
mance coating over an existing floor
bond and effectively adhere After thorough cleaning, acid etching
Grinding/Sanding coating is not optimal and should
to the concrete. Achieving a can be performed to open the be approached with care. There are
Prepares, cleans and abrades
rough sandpaper-like profile pores of the concrete and increase
existing coatings for recoat and
two areas of concerns: (1) lifting or
is ideal. Surface preparation the profile of the surface. Bare wrinkling of the existing coating
helps smooth aggregate floors. A and (2) improper bonding of the
unsealed concrete floors can be
is always best accomplished effectively etched using Corotech
labour-intensive method. new high-performance coating to
with these three elements: V620 Concrete Etch. After etching, the actual concrete or to the
Water Jetting existing coating. If the existing
the acid must be neutralized and
• Cleaning and the floor must be rinsed thoroughly coating is determined to be sound,
Water sprayed at extremely high not peeling, properly bonded to
and allowed to dry. Check local
degreasing. pressure (5,000-40,000 psi) with the concrete, and not subject to
environmental restrictions before
enough force to profile concrete, wrinkling or lifting by the new
proceeding with chemical preparation remove laitance, contamination
• Creating a profile methods. Acid etching will not and unsound concrete. No dust
product, then a thorough cleaning
through acid etching work on surfaces that have been and mechanical abrasion should
is generated, tight spaces can be
treated with sealers and will not be specified to ensure proper
or mechanical methods. prepared and different profiles can
adhesion of the refinish coat to
remove oil, grease, existing coatings, be achieved. Eliminates the need
or other contamination. this existing coat. If the existing
for harsh chemicals. A sufficient
• Patching and repairing. water source must be available,
coating is not sound, then it must
Mechanical Preparation be removed by mechanical
with time required for a thorough
preparation method such as blasting
dry.
Methods such as Shot Blasting, or grinding.
Scarifying, Diamond Grinding, Key Cuts
Grinding/Sanding, Key Cuts and An expert should be consulted
Water Jetting are examples of before attempting to coat over an
Key cuts are masonry saw cuts/
existing coating. 3
APPLICATION

PREPARATION AND HANDLING of rollers (lambskin, phenolic core squeegee, roller lamb’s wool
and porcupine). applicator, or phenolic core roller
Many high-performance products as appropriate. For squeegee
are two-component catalyzed Always refer to product technical application, lightly back roll with a
or unique curing systems that data sheets for application lint-free phenolic core roller perpen-
demand strict adherence to all recommendations for specific dicular to the original squeegee
technical data and guidelines. products and systems, or ask your orientation. Avoid over-rolling as it
Below is a routine checklist of Corotech retailer or Benjamin may cause appearance uniformity
sound practices and procedures. Moore & Co. specialty coatings problems. Since many flooring
representative. systems are multi-layer coats on
• Before beginning, review all large expansive areas, spiked shoes
project specifications closely First Coat – Penetrating Primer/ are routinely used by applicators
and read all product technical Sealer so that they can walk into freshly
data thoroughly. coated areas to re-roll, even-out,
• Stage all materials before starting All new or bare properly lap, blend-in or broadcast aggregate
and double check that all the prepared concrete floors should or other materials into the finish
proper products, components and receive Corotech V155 100% Solids while wet.
quantities are on hand. Epoxy Pre-prime or V156 Quick-
• Carefully follow all mixing Set Epoxy Sealer to provide a Porcupine rollers are used to
instructions and observe all foundation for the coating system smooth the surface coat and
mixing ratios, rates and order of that forms a strong bond with the release entrapped air in the finish.
addition (example: component B concrete, while also satisfying the Notched squeegees and rakes are
High-performance floor is added to component A). thirst and porosity of the substrate. used to apply high solids/high
coatings are specialized • Provide efficient and thorough The reaction of an epoxy sealer build finishes at evenly controlled
products that require mixing of all products and allow with the bare concrete prevents wet film thicknesses. For more
technically accurate for proper “sweat-in” or induction “outgassing” with the subsequent information on specialized application
time. topcoats. Outgassing is a phenom- and finishing tools, one web site to
preparation and handling. • Only mix enough material enon where a liquid coating/top- visit is www.midwestrake.com.
They are often applied by to be applied within the coat reacts with unsealed concrete
trained professional flooring recommended working time or and gas is generated, causing Slip-Resistant Surfaces
applicators with specialized pot-life of the product. bubbles to form that become Hand broadcast aggregate in the
equipment, application • Measure temperatures and trapped in the finished film. V155 intermediate and/or the finish
make sure they are within may be sprayed, brushed or rolled; coat followed by back rolling. The
tools and techniques. allowable application ranges and V156 can be applied with a brush, amount required will be determined
Application tools and note where cold or hot roller or squeegee with back roll. by the size of the aggregate and
techniques vary depending temperatures can slow or desired anti-slip properties. Keep in
on the type of flooring accelerate performance/ Intermediate and Finish Coats mind the more aggregate you use,
application parameters. Pour ribbons of the mixed coatings the harder it will be to keep the
system and are typically • If using thinners, only use onto the floor then spread with finish clean.
categorized as: recommended thinning agents.
• Once the coatings are prepared
• Thin-Film Systems - make sure that the application
tools to be used are high quality,
A two-coat system clean and in good working
consisting of a condition.
penetrating sealer/
primer and finish coat. APPLYING FLOOR COATING
SYSTEMS

• Thick-Film or High-Build Flooring systems can be broadly

Systems - A three-coat grouped into two types: thin film
system consisting of a (5-8 mils) and thick film (13-20
mils) systems. Thin film applications
penetrating sealer, an are usually 2-coat systems and
intermediate coat, and lend themselves to brush, roll (3/8”
a finish coat or a two-coat nap max) and spray. Thick film
system that builds to more applications can be 2- or 3-coat
systems; tool requirements include
than 8 mils dry.
brushes, squeegees and a variety
4
 TROUBLESHOOTING

PROBLEM: Lint or Fibres on data sheets for tools and techniques. away all soft material, follow with sunlight and chemical exposure.
in Coating Possible Causes: a strong solvent wipe-up and Prevention / Remedy:
Improper mixing. Mixing technique remove all residue. If finish is tacky If the problem can be predicted,
Possible Causes: whips air into coating. or sticky in spots, treat localized select colours that are more
Improper roller quality. Prevention / Remedy: areas by scraping or grinding colorfast and/or topcoat with
Prevention / Remedy: Use 300-500 RPM mixing drill and recoat. If surface is uniformly aliphatic urethane. Make sure that
Use high-quality roller cover with with blade that delivers smooth partially cured, allow additional coating system is well designed
composition appropriate for product incorporation. time to cure. to be resistant to the types of
type. Possible Causes: chemicals and exposures that will
Air, surface or material temperature PROBLEM: Poor Wetting of be most prevalent.
PROBLEM: Dirt, Lumps or Trash exceeding 90° F will cause a 100% Coating, Crawling, Fish Eyes,
in Finish solids epoxy floor coating to cure and Cratering PROBLEM: Wrinkling of Film
too quickly, preventing air in the
coating from escaping. Possible Causes: Possible Causes:
Possible Causes:
Prevention / Remedy: Contamination on floor from Solvent is added to the coating
Dust, dirt or shot not effectively
Avoid high-temperature conditions
removed during prep steps. residual materials like silicones, oils, and the coating is applied thickly.
during application when possible.
Prevention / Remedy: lubricants, waxes, animal fats, Finish coating attacks and softens
Cool material before application.
Be thorough with floor clean-up vegetable oils and food products. unknown previous coating,
Possible Causes:
before beginning application. Direct sunlight will cause coating Prevention / Remedy: causing it to lift and wrinkling the
Possible Causes: to cure too quickly. Before application, perform multiple surface film. Surface temperature
Improper mixing of dry additives Prevention / Remedy: sample areas and check inventory of concrete is too cold (below 50° F).
such as anti-slip aggregate. Note excessive temperature and of the types of products and Prevention / Remedy:
Prevention / Remedy: attempt to shade areas from direct potential contaminants that may Avoid adding solvent and exceeding
Be sure to thoroughly incorporate sunlight during application. be encountered at the project film thickness recommendations.
dry additives. Repair: site. Use solvent or chemical Always perform sample test areas
Possible Causes: Bubbles in finish. Thoroughly agents identified as dissolvers for to insure compatibility before
Dirty equipment or containers. abrade the affected areas with materials like silicones that may proceeding.
Prevention / Remedy: scrubber or grinder. Always feather be encountered and degreasers for Repair:
Be sure to properly clean all equipment the edges of all imperfections. oil/grease contaminants in sample Thoroughly sand and/or grind the
and containers. Thoroughly vacuum debris and areas to determine most effective floor to a smooth substrate. Clean
follow with tack rag and/or strong preparation specification. thoroughly, tack rag and solvent
PROBLEM: Bubbles solvent wipe. Recoat at a rate of Repair: wipe. Recoat floor.
in Cured Finish coverage called for on data sheet. Thoroughly sand or grind affected
areas. Remove all residue. Tack rag PROBLEM: Delamination,
Possible Causes: PROBLEM: Coverage Variations and solvent wipe. Re-apply and Flaking, Peeling
Outgassing. Bubbles may occur monitor to determine if condition
after the epoxy coating is applied Possible Causes: is remedied. Possible Causes:
to a porous concrete surface. Temperature, application tool Insufficient cleaning/preparation,
As the coating begins to cure it quality and technique. PROBLEM: Lack of Colour inadequate etching, excessive
releases heat (exotherms), which Prevention / Remedy: Uniformity moisture in and/or on concrete,
causes air that expands, tries to Coverage recommendations are intercoat adhesion failures.
escape and gets caught in the film. based upon well established Possible Causes: Prevention / Remedy:
Prevention / Remedy: performance criteria. When signif- During application, insufficient The testing and evaluation
Apply V155 Corotech100% solids icant coverage variations occur, mixing/pigment settling. Multiple phase of the project is intended
penetrating epoxy sealer as first consult data sheet information and to determine the best possible
batches at project site. Product
coat. adhere closely to specifications.
settling. Improper blending of cleaning and preparation speci-
Problem:
Possible Causes: components. Inconsistent application fications. These steps combined
Gummy or Tacky Spots in 2-Component
High air flow. Excessive air flow techniques. with multiple sample areas are the
Coating After 24-Hour Cure
originating from external sources Prevention / Remedy: most tried and true approaches to
Possible Causes:
and equipment causing rapid No catalyst or part B used, insuf- Mix properly and thoroughly prior achieving successful results with
surface dry of the coating, which ficient mixing of components or to and during application. Always your high-performance flooring
entraps air. improper ratio of components to segregate lots when practical and system. We strongly recommend
Prevention / Remedy: be mixed. box material where appropriate. not compromising these aspects of
Remove or re-direct sources of air Prevention / Remedy: Find break points (like expansion the process.
convection during drying. Be certain all components are used joints) when changing lots. Use Repair:
Possible Causes: at proper ratios and mixed well per consistent finish application Shot blast entire floor to bare concrete
Roller covers of poor quality or data sheet guidelines. techniques particularly in back when extensive delamination, peeling
incorrect nap and/or composition. Repair: rolling to minimize variations. or flaking is encountered.
Prevention / Remedy: If coating is gummy because part Possible Causes: Repeat original specification. For
Adhere closely to recommendations B catalyst was not added, scrape In service, prolonged exposure to isolated areas, key the affected
5
area with a sharp knife or 1/16” • Keep the floors clean with
portable saw and repeat specification frequent sweeping and
in isolated area only. vacuuming.
PROBLEM: Dull or Low Gloss • Wash the floors on a regular
After 24-Hours Cure basis to remove dirt, grease,
grime and other residue. This
Possible Causes: prevents the embedding of
Poor ventilation, excessive humidity, these contaminants into the
cold temperatures. coating that can occur with
Prevention / Remedy: extensive wear and constant
Avoid these conditions if possible traffic.
or alter air flows, dehumidify or • Always remove spills as soon
artificially elevate temperatures as they occur. Even though
during application. your high-performance
Repair: flooring system is highly
If a “blush” occurs over surface resistant to many chemicals,
(greasy film) after curing, scrub leaving them unattended for
with strong pH neutral detergent prolonged periods is not safe
or wipe with strong aromatic solvent and may discolor and/or
like xylene. If recoat time has soften the finish.
elapsed, sand or grind floor, clean • Acid and caustic spills should
thoroughly before recoating. be cleaned and neutralized
immediately. Always follow-up
TIPS FOR CARE AND with a thorough rinse.
MAINTENANCE
To learn about the entire portfolio of
Once your high-performance Floor Corotech high-performance primers,
System has been installed, here are enamels, epoxies, urethanes and more,
some basic tips that are useful to visit benjaminmoore.ca or talk to
achieve an optimum service life. your Corotech retailer.

Benjamin Moore & Co., Ltd.

8775 Keele St., Concord, ON L4K 2N1 • benjaminmoore.ca
0 23906 33948 7
©2016 Benjamin Moore & Co., Limited. Benjamin Moore and the triangle “M” symbol are registered
trademarks of Benjamin Moore & Co., Limited. All other marks are the property of their respective owner. M2440615CE 6/2016