Flooring Options for High Traffic Areas

1
Flooring Options for High Traffic Areas

• Presented by
• Jayson L. Helsel, P.E.
• KTA-Tator, Inc.

2
Flooring Options Overview

• Moisture assessment
• Surface preparation
• Coating options
• Slip resistance

3
Learning Objectives

• Completion of this webinar will enable the
  participant to
• Describe two typical moisture tests for concrete
  floors and what the common acceptance criteria
  are for each
• List typical surface preparation methods used
  for concrete floors prior to coating application
• Identify at least three common options for
  coating concrete floors subjected to foot traffic
• Understand general slip resistance requirements
  and list the common minimum value necessary for
  coefficient of friction

4
Moisture Assessment

• Plastic sheet method ASTM D4263
• Calcium chloride test ASTM F1869
• In-Situ Relative Humidity ASTM F2170
• Moisture meters F2659 F710

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Moisture Assessment

• Plastic sheet method (ASTM D4263)
• Square sheet of clear plastic film taped to the
  slab surface
• Remains for 16-24 hours
• Look for moisture development

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Moisture Assessment

• Calcium chloride test (ASTM F1869)
• Determines vapor emission rate in pounds/1000 sq
  ft/24 hrs
• Known mass of anhydrous calcium chloride placed
  under sealed dome
• Remains 60-72 hours
• Weight increase determines amount moisture
• Typical limit 3 lbs/1000 sq ft/24 hrs

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Calcium Chloride Test

• Quantifies volume of water emitting from a 1000
  square foot slab per 24 hours
• Plan the test
• Prepare the test site (CSP 1-2)
• Weight cartridges record weights
• Open cartridges
• Place cartridges, domes and seal domes
• Start testing
• End test reweigh and calculate results

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Calcium Chloride Test
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Calcium Chloride Test

1. Record start and stop dates and times
2. Record pre- and post-test weights. Calculate
   weight gain
3. Multiply weight gain by constant (118.932), then
   divide by elapsed time of test

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Moisture Assessment

• In-situ Relative humidity in slabs (ASTM F2170)
• Holes drilled to 40 (one side) or 20
  (two-sided) of slab thickness
• Plastic inserts or probes inserted and sealed
• Measure after 72 hours
• 75 is typical maximum (ASTM F710)
• Coating manufacturer may specify maximum

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Moisture Assessment

• Moisture meters
• Intended for floors/slabs (and walls)
• Operatesby measuring the electrical resistance or
  conductivity between the tips of two insulated
  pins at the surface or subsurface using concrete
  nails
• Resistance converted to a relative moisture
  content
• Testing destructive when holes must be drilled

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Moisture Assessment

• Moisture meters
• Some types non-destructive, use electrical
  impedance measurement
• Contacts rest on concrete surface
• May also report humidity
• Mostly used prior to flooring application

13
Surface Preparation

• Perform thorough assessment
• Need sound surface
• pH measurement
• Specify appropriate patching materials
• Cementitious products epoxy, urethane
• 100 acrylic products

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Surface Preparation

• Surface cleaning to remove grease, oil,
  contaminants, etc.
• SSPC-SP 1
• ASTM D4258
• Air, water cleaning, scrubbing, sweeping or
  vacuuming may be acceptable

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Surface Preparation

• Blast cleaning
• Lower pressures
• SSPC-SP 13
• ASTM D4259
• Variations
• Centrifugal wheel blast unit, e.g. Blastrac

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Surface Preparation

• International Concrete Repair Institute (ICRI)
• Technical Guideline No. 310.2-1997 (formerly No.
  03732), Selecting and Specifying Concrete
  Surface Preparation for Sealers, Coatings, and
  Polymers Overlays
• Defines levels of preparation based on surface
  profile roughness
• Includes surface replica comparison panels

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ICRI 310.2

• Concrete Surface Profile, CSP 1 - CSP 10
• CSP 3 to 5 typically specified for floor coatings

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ICRI 310.2

• CSP 3 Light shotblast

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ICRI 310.2

• CSP 5 Medium shotblast

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ICRI 310.2

• CSP 6 Medium scarification

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Surface Preparation

• Hand/power tools
• ASTM D4259
• Smaller areas
• E.g. rotopeen

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Surface Preparation

• Acid etching
• ASTM D4260
• Surface must be free of
• Sealers, coatings, grease, oil, etc.
• Typical acids
• Hydrochloric, sulfuric, phosphoric, citric
• Thorough removal of spent acid

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Surface Preparation Inspection

• Uniform and clean surface
• Sound concrete
• Surface pH
• Moisture content

24
Coating Options

• Polished concrete
• Epoxy
• Methyl methacrylate acrylic (MMA)
• Polyurea/polyaspartic
• Polyurethane
• Moisture cured polyurethane
• Cementitious urethane

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Polished Concrete

• Densifier to increase surface density and
  abrasion resistance
• Penetrating alkyl silicate/siliconate product
• Micro film forming surface treatment (sealer)
  optional
• Polishing/honing of floor
• Color may be added
• Regular cleaning required

26
Polished Concrete

• Limited chemical resistance
• Typical applications
• Big box stores
• Grocery stores
• Mall stores
• Office lobbies

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Polished Concrete
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Epoxy Coatings

• Variety of epoxy chemistries
• Polyamide, polyamine, novolac
• Typically 100/high solids
• Typical system
• Epoxy primer
• Epoxy base coat(s)
• Aggregate broadcast typical
• Decorative broadcast possible
• Topcoat/sealer (optional)

29
Epoxy Coatings

• Product example
• Surface preparation Mechanical profile
  (blasting) equal to 30-50 grit sandpaper
• Application by trowel/squeegee back roll
• Primer Epoxy at 4-8 mils DFT
• Basecoat Epoxy at 60-75 mils
• Broadcast coat Epoxy at 60-75 mils
• Topcoat Epoxy at 8-12 mils

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Epoxy Coatings

• Product example (self leveling)
• Surface preparation Mechanical profile
  (blasting) equal to 30-50 grit sandpaper
• Application by trowel/squeegee back roll
• Primer Epoxy at 4-8 mils DFT
• Topping Epoxy, pour/spread to 250 mils
• Topcoat Epoxy at 4-8 mils

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Epoxy Coatings

• Product example (thinner film)
• Surface preparation Mechanical profile
  (blasting) equal to 50-80 grit sandpaper
• Application by trowel/squeegee back roll
• Primer Epoxy at 5-8 mils DFT
• Topcoat Epoxy at 8-16 mils DFT

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Epoxy Coatings

• Typical applications
• Commercial kitchens
• Restaurants
• Grocery/food preparation
• Restrooms
• Office/apartment lobbies

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Epoxy Coatings
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MMA Coatings

• Methyl methacrylate acrylic chemistry
• Typical system (125 mils total DFT)
• Moisture 85 Max RH
• Surface preparation ICRI 310.2 CSP 5
• Roller application
• MMA primer
• MMA basecoat with quartz broadcast
• MMA topcoat (2 coats)

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MMA Coatings

• Typical applications
• Commercial kitchens
• Grocery stores
• Laboratories
• Animal holding
• Manufacturing/processing

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MMA Coatings
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Polyurea/Polyaspartic Coatings

• 100 solids aliphatic polyurea/ polyaspartic
• Product example
• Surface preparation Mechanical abrasion
• Application by trowel/squeegee
• Primer Epoxy at 2-3 mils DFT
• Basecoat Polyurea at 8-12 mils DFT
• Vinyl chip broadcast option
• Topcoat Polyurea clearcoat at 8-12 mils DFT

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Polyurea/polyaspartic Coatings

• Typical applications
• Commercial kitchens
• Restaurants
• Grocery stores
• Restrooms

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Polyurethane Coatings

• High solids aliphatic polyurethane
• Product example
• Surface preparation Mechanical abrasion/acid
  etch
• Application by roller
• Primer Epoxy at 2-3 mils DFT
• Basecoat(s) Polyurethane at 2-4 mils DFT,
  multiple coats typical

40
Moisture Cured Polyurethane Coatings

• Single component aliphatic MCU
• Product example
• Surface preparation Mechanical abrasion/acid
  etch
• Application by roller
• Primer MCU or Epoxy at 2-3 mils DFT
• Basecoat(s) MCU at 2-4 mils DFT, multiple coats
  typical

41
Polyurethane/MCU Coatings

• Typical applications
• Showrooms
• Cafeterias
• Laboratories

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Cementitious Urethane

• 100 solids aromatic cementitious urethane
• May have broadcast aggregate
• High abrasion resistance
• High chemical resistance

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Cementitious Urethane

• Product example
• Moisture 20 lb Max CaCl2 or 99 Max RH
• Surface preparation ICRI 310.2 CSP 4-5
• Application Trowel applied at 250 mils
• Optional topcoat, with or without aggregate
  broadcast

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Cementitious Urethane

• Typical applications
• Commercial kitchens
• Processing areas
• Pharmaceutical
• Wet areas
• Exterior

45
Cementitious Urethane
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Slip Resistance

• Utilize flooring material that has acceptable
  slip resistance under foreseeable conditions
• Applicable regulations for required Coefficient
  of Friction (COF) are not always clear

47
Slip Resistance

• Typical recommendations include
• 0.5 COF by ADA and OSHA
• 0.6 COF recommended for accessible routes
• 0.8 COF recommended for ramps

48
Slip Resistance

• Many test methods and corresponding equipment for
  measuring slip
• Testing equipment
• Drag sled machines
• Articulated strut machines
• British pendulum
• Others

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Slip Resistance

• Test methods (partial list)
• ASTM F1677, Portable Inclineable Articulated
  Strut Slip Tester
• ASTM F1679, Variable Incidence Tribometer
• ASTM C1028M, Static Coefficient of Friction of
  Ceramic Tile and Other Like Surfaces
• NFSI B1010.1-2009, Test method for Measuring Wet
  SCOF of Common Hard Surface Floor Materials
• ASTM F609, Horizontal Pull Slipmeter

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Summary

• Moisture assessment
• Surface preparation inspection
• Coating options
• Slip resistance