Recoating an entire concrete floor is a huge undertaking, costing a great deal of money and requiring a significant amount of time and resources. While sometimes a re-coat is the only solution, other times, repairing only the damaged concrete substrate is possible, especially when using the right product. Floor-Clad Concrete Repair Kit is designed for use by facilities managers and/or epoxy flooring contractors as a solution to repair large holes, cracks or divots in concrete floors without having to re-coat the entire floor area. This solution is perfect in situations where the damage is isolated to specific areas throughout the facility and/or when time, money and resources are not available for a facility-wide re-coat.
The Floor-Clad Concrete Repair Kit is comprised of ½ gallon of Floor-Coat pigmented epoxy coating Part A (resin in a medium gray color), 1 quart of Floor-Coat pigmented epoxy coating Part B (hardener) and approximately 40 lbs of custom blended aggregate. All of this is packaged and shipped in a 5-gallon pail for the customers’ convenience.
In addition to the kit, a separate 5-gallon pail and a slow-speed drill mixer are required for the installation of Floor-Clad Concrete Repair. These items are not included in the kit.
Testing and Prep
Just as with any epoxy resin product, moisture testing and surface preparation are a must prior to application. Moisture issues will cause coating failures, so Epoxy Floor Supply recommends using the plastic sheet method, a calcium chloride test or a relative humidity test to ensure that the moisture levels are low enough to proceed.
After the moisture test has been completed, proper surface prep is required. The surface must be clean and sound, with all dirt, oil, grease and loose substrate matter must be removed. A proper profile must be achieved by mechanical means only – either diamond grinding or shot blasting. Once the excess dust is vacuumed from the concrete floor, all edges of walls and terminating edges of the floor must be taped to ensure ease of application.
The installation of Floor-Clad is simple, especially when compared to a re-coat of an entire facility floor. After removing Floor-Coat Part A (resin) and Part B (hardener) from the 5-gallon pail, combine them in a separate, clean pail. The ratio is 2:1, so the entire ½ gallon of Part A will be combined with the entire ¼ gallon of Part B. Mix the resin and hardener with a slow-speed drill mixer for 30 seconds to a minute. Once Part A and Part B are thoroughly mixed together, slowly add the aggregate and continue mixing with the slow-speed drill mixer for an additional 2-3 minutes.
After the mixing process is complete, apply the material to the application area with a trowel. The Marshalltown 4-inch by 12-inch finish trowel is recommended. Floor-Clad can be applied as thick or thin as desired. The coating typically cures within 8 to 12 hours at 70 degrees Fahrenheit. Cure times will vary based on ambient temperature.
Although the application of Floor-Clad is relatively straight-forward, the product should only be installed by trained and competent personnel familiar with epoxy resin application. In addition, safety attire must be worn at all times. Safety attire includes safety glasses, protective gloves and long-sleeved shirts. During the surface preparation process, a dusk mask must be worn as well.
For more information about the Floor-Clad Concrete Repair Kit or any other Epoxy Floor Supply products, please visit the Floor-Clad Concrete Repair Kit page.