Floor Application Guidelines

ZeraDur™ garage floor kit is self-priming. It is recommended to use in a 2 coat application; the first coat is to seal the concrete from outgassing (to be applied very thin) whereas the second coat is to produce the durable non-slip finish. ZeraDur™ should be applied over clean, sound, dust free surfaces.

Preparation:

Remove all items from the garage and thoroughly sweep all dirt and dust.
Ideally before you start, the outside temperature should be between 18°C to 26°C, relative humidity below 80%, and the garage floor should be protected from wind-blown debris.
You must precondition the material @23C for 24 hours prior to the application to prevent problems of higher viscosity (thicker material) and slow curing during the winter or very fast setting during the summer.
Tape off walls, any baseboard trims, posts, floor draining plates and door thresholds as well as the area directly underneath the garage door with masking or duct tape, allowing you to shut the door overnight. This is intended to keep out dust. Tape across the doorway, leading to the garage from the house.
When you start applying ZeraDur™, use a trim pad to cut coating along the edges.

For best results, surface should be prepared as follows:
Concrete Slab Preparation:

Concrete should be a minimum of 28 days old. Regardless if the concrete is new or old, it has to be prepared properly for a successful installation. The most effective way for preparation of the garage floor is to use a shot-blasting technique, or another means of mechanical abrasion to ensure a thorough and deep profile for adhesion.

Alternatively, an acid-etching technique can be used providing care is taken regarding the safe handling of the acid and avoiding contamination of the adjacent surfaces such as walls, doors, driveways, etc. A combination of acid-etching and power washing can also be used. Remove oil, grease, dirt and any unsound concrete using a combination of commercial degreasers and alkaline wash.

For severely damaged concrete, use ZeraFloor™ (3-part system) epoxy patching and leveling material (see data sheet for details).

Removing Oil & Grease:

Pour a quality commercial de-greaser or Trisodium Phosphate (TSP) on the stain. Let the detergent sit for 45 minutes, then pour boiling water on the area and vigorously scrub the stain section with the broom.
Conduct the "water test"; mist water over the stain and if the water beads, repeat the same treatment again.

Old Painted Concrete:

If previous epoxy coating is well bonded, scuff sand the surface after cleaning to ensure a tight bond between the two coatings. Rinse thoroughly. Latex paints, oil-based paints or sealers must be removed using grinding or other mechanical means. Over a sound old epoxy coating, the surface must be sanded to ensure good adhesion.

Moisture in the Concrete:

Apply 2'x2' sheet of plastic to the area of the garage floor. Tape down the edges with duct tape and allow to set for 24 hours. If water droplets appear on the inside of the plastic or if the concrete appears wet , moisture is trapped in the concrete and the floor should not be painted.

Repairing the Cracks (if applicable):

First thing in the morning, after the floor has dried out, fill 1/4 in. cracks and larger holes or spalled areas with ZeraBond™ (epoxy crack filler). Use a plastic putty knife or triangle wide spatula to scrape the surface level and smooth. Let this dry for 8-12 hours before you begin applying the coating.
Most large area concrete floors have joints and seams, which allow for movement and expansion. Do not fill these cracks with an epoxy garage floor coating, but rather with an epoxy gel, such as ZeraBond™.

SURFACE PREPARATION

Either by mechanical means or an acid-etching technique.

APPLICATION

ZeraDur™ is applied in a 2-coat application.

AREA PREPARATION

For optimal performance, both the coating and substrate should be maintained at 18? to 30? C (68 to 86?F) for 24 hours prior to beginning work. The same temperature range should be maintained during mixing, application, and curing.

Application in direct sunlight and rising surface temperatures may result in blistering of materials due to expansion of entrapped air or moisture in the substrate. Concrete that has been in direct sunlight must be shaded 24 hours prior to application and remain shaded until after the initial set. Avoid the application during high humidity above 90%.

OUTGASSING

To minimize outgassing (formation of large bubbles and craters) you must apply the first coat thin using a flat squeegee then a roller, to level the coating and push it into the voids of the concrete floor. You must keep the garage door closed to prevent the sun from warming the floor which could worsen the outgassing. Apply the first coat early in the morning or late in the afternoon.

Mixing

The mixing equipment used to mix the coating must be clean and free of any contaminants that may be present in the equipment from previously used products:

Premix component "A" of ZeraDur first to eliminate the possibility of settlement. Pour all of the liquid from Part B into a Part A container.
Mix thoroughly using a slow speed drill equipped with a mixing blade for one minute until the color is uniform. If a non-slip finish is required, add the non-slip additive (provided inside the one gallon kit) into the mixed material and disperse for at least another two minutes. Make sure to scrape the sides of the can into the coating and mix it well to prevent the formation of tacky (gummy) patches in the coating, which will never firmly dry.

Application

For the first coat (priming coat): immediately pour some of the mixed material onto the edges of the prepared floor and spread the material thin using a flat squeegee, then back roll to force the material onto the porosity of the concrete.
For the second coat: immediately pour some of the mixed material onto the edges of the prepared floor and spread the material using a lint free 6 mm nap roller to provide an even coat.
Allow the topcoat to cure thoroughly for 24 hours for foot traffic. Colder temperature will take longer to set and warmer temperatures will shorten the time to cure. It takes 7 days to achieve a full cure (full service). Keep water, cleaners and other liquid spillage away from the coating for at least one week.

CAUTION: Avoid the application of ZeraDur™ under direct sunlight to minimize the occurrence of bubbling (from outgassing).

LIMITATIONS

Do not apply on untreated floors; the concrete must be prepared by shot-blasting or an equivalent technique, or acid etched for proper adhesion.

Do not apply on tacky primer; the primer coat must be dry and firm.
Do not apply if the level of moisture in concrete is high.
Do not apply over poorly-bonded previous paint.
Not recommended for exterior applications.
Do not hand-mix the coating.
Do not leave the mixed materials in the can for a long period time (particularly during the summer time) otherwise the coating will harden in the can.
Slow curing product; requires 3 days for vehicular traffic.
Do not subject the coating to water, cleaners or chemicals for at least 7 days after application.
For a non-slip finish, do not apply the coating heavily, otherwise the finish will not be non-slip.
Outgassing may occur from time to time due to poor quality of concrete; apply at least two thin coats of ZeraDur™ to seal the concrete from outgassing; a third coat may be necessary in some cases to produce the desired smooth finish.
The product has a slight "orange peel" finish if applied in a thin film.