Case Study: Site Applied Polyaspartic Garage Floor Coatingpda-europe.org/documents/1_Karl_Wuehrer.pdf · 3040 Grit Diamonds Final Profile: ICRI CSP 2-3 . PDA Europe 2014 Annual Conference

PDA Europe 2014 Annual Conference – Krakow, 5-7 November

Case Study:

Site Applied Polyaspartic

Garage Floor Coating

• From Great Raw Materials Come Great Coatings

Steven Reinstadtler, Bayer MaterialScience LLC, USA

presented by Karl H. Wuehrer , Bayer MaterialScience AG, D


Case Study: Site Applied Polyaspartic Garage Floor Coating

Agenda Introduction to Market Area

The Technology: Polyaspartic Review

Original Site and Surface Preparation

Original Coating Procedure and Application

Case History: Observations

Applications for Other Adjacent Markets

Questions and Answers



Introduction to Market Area

During a lean economy, people want to enjoy more usable space in

a clean, professional looking area without purchasing a new home

Protects concrete from contaminates

• Road Salt: Can cause spalling and general concrete

degradation

• Motor Oil/Antifreeze: Can stain surface and get tracked into

home later

Provides aesthetically pleasing space

• Decorative finish brightens area and adds color

• Protects against hot tire staining of concrete

• Expands usable space in a home

Residential Garage Floor Market Drivers



Polyaspartic Coatings: High build, fast curing floor coatings

with excellent clarity, gloss and longevity

The Technology – Polyaspartic Review

“Paint on Steroids”

• Many decorative floor coatings are less than 4

mils thick

• Polyaspartic technology allows for thick, high

build finishes

• The saying, “Like watching paint dry” means

more labor time

• Cure times are greatly improved and allow for

faster return-to-service

• Proven 15+ year record in industrial

maintenance applications




Chemistry:

2K aliphatic polyurea based on polyaspartic resins and aliphatic

isocyanates

OCN

NCO Polyaspartic Resins Aliphatic Isocyanate

React to form

A Polyaspartic Coating




Benefits:

• Excellent durability

• Fast return-to-service time

• High build per coat

• Labor savings

• VOC compliance

• Extends application season

• Excellent „color pop‟ on

decorative stained floors

Limitations:

• Difficult to downgloss

• Smaller batches must be

mixed

• Two component requires a

mixing step




Typical Characteristics:

• Excellent color/gloss retention

• Dry Film Thickness: 125 – 375 µm.

• Hardness: 60 to 80 Shore D

• Mix ratio: 2:1 to 1:1 by volume depending on formula

• Working time: typically 30-60 min. at 23°C/ 50% RH

• VOC: near zero to 100g/L

• Taber Abrasion: 25 - 60mg (CS-17)

• Elongation at Break: 4 - 100%

• Dry Time: 2 hours (Gardner Circular – 23°C/ 50%RH)




Surface prep is key to any concrete floor coating job

Site logistics was considered first: Location of access points, switches, day joints,

and drains were noted. Temperature and humidity noted.

Existing slab was inspected: Contractor looked for cracks, spalling, porosity,

soaked-in contaminants. Oil or coolant stains were cleaned.

Surface grinding starts: Contractor found the concrete to have a high hardness so

extra weight was added to the machine.

Relief joints were cleaned out and filled: Joints were ground in order to enhance

adhesion then were filled with polyurea caulk




Page 9

Concrete Surface Grinding: - Yields a consistent, sharp profile

- Doesn‟t micro-fracture the surface like blasting

- Doesn‟t leave residual contaminates like acid etching

HTC 500 Planetary Grinder

First Pass:

1820 Grit Diamonds

Second Pass:

3040 Grit Diamonds

Final Profile: ICRI CSP 2-3




Page 10

Joint Filler and Repairs:

- Polyurea joint filler allowed low temperature cure and fast trimming

- Need balance of elongation, hardness, and compressive strength

- Eliminates area for dirt accumulation – cleaner look

Two Component

Electric Drive Caulking

Gun

- Aliphatic Polyurea

Joint Filler

- Trimmed at 15-20

min.




Page 11

Coating System Build Up

Gray Polyaspartic Basecoat: Seals and bonds to prepared concrete surface

Broadcast of Decorative Paint Chips: Adds depth to decorative element

Clear Polyaspartic Topcoat: Locks the look in under a light stable finish

Process was applied to one half of

garage first, then the other half




Basecoat: 3/32” notched squeegee, back rolled with 3/8” nap roller, 8-12 mils WFT

Decorative Chips: Full broadcast into wet basecoat, 1/8”-1/4” three-color-blend chips

Topcoat: 3/32” notched squeegee, back rolled with 3/8” nap roller, 10-12 mils WFT




Job Completed Late Fall 2010: 80 m² garage space, South facing site

Air Temperature was 2ºC, concrete floor temperature was 7ºC

- One garage door open during application for ventilation

- Snow flurries present during the installation!

After applying the basecoat and chips, the floor cured for 1.5 hours

- Chipped finish was dragged with heavy bar

- Excess chips were vacuumed up

The clear topcoat was allowed to cure before re-entering the jobsite:

- After two hours the floor accepted foot traffic

- After six hours, vehicle was parked in garage

Additional Project Details:




Page 14

Site Observations: 3.5 years after installation

• 95%+ gloss retention – At garage opening

• 100% color retention – At garage opening

• No hot tire staining – Bay 1 contains sports car, performance tires

• No hot tire pick up – Bay 2 contains heavy off-road vehicle



Page 15

Site Observations: 3.5 years after installation

• No chemical staining – Vehicle and lawn mower oil easily wiped off

• No road salt damage – Northeast location means salt in winter

• No cracking or blistering – Coating is intact over filled joints




Homeowner Observations: 3.5 years after installation

“It’s nice to be able to hose the salt and road ash down the drain”

“ I’ve used the new space as the eating area for a communion and

confirmation party – and I’m not embarrassed”

“Seamless floor is a plus since there isn’t that joint that collects dirt and

leaves, easier to sweep up”

“I feel like I put on an addition to the house”




Applications for Other Adjacent Markets

Page 17

• Parking Decks: Fast cure means shorter return-to-service time

and less revenue loss

• Commercial Space: Hotels and restaurants like the decorative

finishes and quick installation

• Stadiums and Other Venues: Preferred for gloss and color

retention as well as cleanability and durability

- Similar areas have similar needs -



Bayer MaterialScience AG

CAS

Steven Reinstadtler, USA

Karl Wuehrer, D


10% sovent

Mainly Co-resin

lower reactivity

NH

1220

NH

1420 NH

1520

NH

2850XP

Lower viscosity

higher reactivity

Lower viscosity

lower reactivity

NH

1521

Desmophen® Type Supply form Equivalent weight Viscosity [mPas]

Gel Time

NH 1520 Aspartic 100% 290 1200 8 h

NH 1521 Aspartic 90% in BA 326 160 8 h

NH 1420 Aspartic 100% 279 1000 1 h

NH 1220 Aspartic 100% 230 ≤ 100 < 5 min

NH 2850 XP Aspartic 100% 290 100 1.5 h

Back up: Product range Polyaspartic Coatings


Back up: Product range Polyaspartic Coatings

Desmodur® Type Supply form

NCO content

Viscosity [mPas]

UV-stable

N 3600 Trimer 100% 23.0% 1200 yes

N 3800 PES-Prepolymer 100% 11.0% 6000 yes

N 3900 Asymetric Trimer 100% 23.5% 730 yes

E XP 2599 PET-Prepolymer 100% 6.0% 2500 no

Flexible N

3900

N

3600 N

3800

Hard

E XP

2599

Flexible

Viscosity decrease

Documents

Case Study: Site Applied Polyaspartic Garage Floor Coatingpda-europe.org/documents/1_Karl_Wuehrer.pdf · 3040 Grit Diamonds Final Profile: ICRI CSP 2-3 . PDA Europe 2014 Annual Conference