If you have decided to start painting a concrete floor, proper application is crucial for the effectiveness and longevity of the concrete floor paint or sealer. Here is a guide with some tips, to help the process of a successful application.

Preparing Concrete Floors

Thoroughly clean the floor to remove any surface debris, dirt, dust, and especially oil and grease stains. This step is essential as any dirt or other debris left will prevent the paint or sealer from adhering to the solid concrete substrate below.

If necessary, etch the concrete to ensure proper adhesion of the sealer. Etching involves using an acid-based solution such as Polycote Etch IT to remove the weak laitance and dust.  The etching solution will also help create a keyed texture to a smooth surface which then helps the sealer to penetrate and bond effectively to the substrate.

If the floor is already painted with a concrete floor paint, even an epoxy paint, make absolutely sure the old paint has fully adhered to the concrete surface, before painting a fresh coat over the top. If it is flaking or not adhered well, make sure it is fully removed (a wire brush will make this an easy job and is ideal for this), otherwise you are headed for failure. If you do paint over the top of old paint that is loose, even with an epoxy concrete coating, the end result will be no different than painting over a sheet of paper! Frankly, an utter waste of time and money!

For larger industrial sized floor areas, the professional way to prepare a concrete surface is to use a vacuum assisted shot blaster or diamond grinder. We have approved installers able to complete this work for you. Alternatively, we are able to hire the machinery for you to complete the work using your own labour and elbow grease. Diamond grinders can also help smooth out worn or poorly laid concrete in order for you to achieve a smooth finish.

Oil and any other contaminants must also be cleaned from the surface of concrete floors. Polycote Degrease IT is an excellent product to help remove contamination or other concrete stain. Degrease It is designed to lift the oil from the surface which can then be washed away with clean water and/or can be removed using a suitable aqua vac machine.

It is best to allow the concrete surfaces to dry as much as possible before applying the chosen concrete paint or concrete sealer.

Repairing Holes And Cracks

Repair any cracks or imperfections in the surface of the substrate prior to the application of the concrete floor paint. Cracks can compromise the effectiveness of the sealer and allow moisture to seep through, leading to potential damage. Fill in the cracks with a suitable low viscosity resin such as Crackfiller EP100. Fine blemishes and small holes can be filled with products such as Easi-fil which is a tough and extremely durable product that can be trowelled super smooth and will dry in less than 30 minutes.  Finally for larger holes, where maybe you might have impact damage or where bolts have been removed from the floor, products such as Cretex EP require minimal experience and will prove to be quick and easy to use.

Should you need to fill holes that are contaminated with oil on a garage floor for example, our Cretex OT Mortar is a highly specialised epoxy resin floor repair that includes oil tolerant resins in order to adhere to oil contaminated floors.  This should be included in your ‘must have supplies’, especially in garages and engineering workshops.

Allow any crack fillers or patching compounds to dry completely before applying the sealer coat.

Ensure Substrate Is As Dry As Possible

First and foremost, if you are intending to use a solvent based paints such as Flortex PU, it is crucial to ensure that the concrete floor is completely dry.  Solvent based products will not adhere to damp surfaces.

Water based Paints such as WD Primer, Flortex SG or Flortex Clearseal will adhere to damp concrete surfaces. However, even though they are tough and durable, we still strongly advise to have the floor as dry as possible and the reason for this is very simple:  If the floor is wet, the pores or the concrete are ‘filled’ with water and thus, the chosen primer will achieve little to no penetration of the substrate. The concrete paint will achieve far better adhesion and be far longer lasting if it is allowed to penetrate and ‘lock’ well into the substrate. Apart from this, any moisture left on the surface prior to application of the sealer may well result in an uneven finish as well as a poor or even non-cure situation.

High build and pure epoxy paints such as Flortex Professional and Flortex EP, should all be applied to a dry floor. If any water or dampness has been in the area, it is always advised to allow the surface to air dry for at least 24 hours and ensure there if appropriate air circulation. Of course, the use of dehumidifiers or fans, or raising the ambient temperature with the use of heaters, can all help speed up the drying process prior to painting concrete.

Has Your Floor Got A Damp Proof Membrane (DPM)?

A damp proof membrane is normally a plastic sheet that has been laid under the concrete in order to prevent damp rising up for the ground below. In older houses, this might have been a layer of bitumen or pitch.

If you have any evidence of rising damp, it is vital that you apply a DPM Primer as the first coat to prevent the water from rising and bubbling up through the chosen top coat. If the surface is very porous, it may be advisable to apply two coats. Concentrate on the edges of the room to make certain you have achieved a good seal. Remember, just one pin hole is all it takes to empty a swimming pool! If you are unsure as to rising damp, a moisture test would be advisable that will show if there is an excess moisture present within the substrate.

Is Your Concrete Showing Any Signs Of Oil Contamination?

If you have any oil contamination within the concrete, particularly on garage floors, standard paints, including epoxies and polyurethanes, will NOT stick. You MUST clean the area of any oil contamination. If you need a degreaser to help accomplish this, especially stubborn oil, Polycote Degrease IT is an excellent product to lift the oil from the floor so that you can clean this away thoroughly.

We then strongly advise the use of Polycote OT Primer, which is an oil tolerant primer which has been professionally formulated to adhere strongly to oil contaminated concrete. You must remember that the oil has sunk down into the pores of the substrate and even after cleaning the floor, the underlying oil will rise by capillary attraction and simply lift the paint you hope to apply. This is very reason why thousands of companies cannot get the paint to stick!

Rest assured, Polycote OT Primer will solve this issue. However, if the surface is very porous, it may be advisable to apply two coats in order to completely seal the surface.

Applying The First Coat Or Primer Coat

First and foremost, it is essential to read and understand the application instructions as stated on the product data sheet BEFORE proceeding. Different floor paint and sealers can be applied similarly by paint roller, brush, squeegee, or sprayer. Each paint type will have different application methods, coverages and drying times. Again, the product data sheets will have all of the information you need prior to painting.

It is important to apply enough primer to be able to penetrate the surface to not only seal the concrete but to allow a good bond. It is always advisable to apply an even coat as much as possible. However, you will almost always find that some parts of the floor are more porous than others. This will be why the first coat might appear patchy. The paint will soak into some areas due to the concrete being more porous, whereas in other areas where the concrete is denser, the paint starts to build on the surface and has begun to show a nice even sheen. This is all perfectly normal, and the second coat should then achieve a nice even finish.

Apply the paint evenly, working in small sections. Start from one corner of the room and work your way towards the exit to avoid stepping on the freshly applied sealer. Ensure that the sealer is applied evenly and without leaving puddles or streaks.

Applying The Top Coat

It is important to wait for the first coat to dry completely BEFORE applying the second coat.  If the substrate is really porous, then it may be advisable to apply a second coat. This is particularly relevant when using Polycote DPM Primer or Polycote OT Primer. Indeed, should any further coats be required, allow the existing coat to cure before continuing with any further applications.

If you have high traffic areas, a high build epoxy top coat such as Flortex Professional would be highly recommended.

Avoid over-application and brush out any puddling, as this may lead to a uneven paint finish.

How To Achieve A Non Slip Finish

Almost all of our top coats have an anti slip option available. This is where the ‘standard’ coating is supplied with a non slip aggregate that is either mixed in with the paint prior to application, or can be sprinkled onto the first coat whilst it is wet and then the second (top) coat is applied over to completely seal in the aggregate.

You may well have been frustrated in the past due to the so called non slip paint becoming smooth after only a short period of time and this is simply due to the poor strength of the aggregate used to achieve a slip resistant finish.  The calcined bauxite aggregate we supply, has one of the highest levels of shore hardness with a Mohs level of 8.5. and can withstand both constant and heavy traffic, and still maintain good slip resistance for many years. For more information on the Mohs levels, see https://www.nps.gov/articles/mohs-hardness-scale.htm

Curing And Drying Times

After applying the sealer, allow it to cure and dry according to the manufacturer’s instructions, before allowing use of the area. Remember that the curing and drying time can vary greatly depending on the environmental conditions as well as the type of sealer used.

To allow for the correct and sufficient curing times will ensure the sealer not only bonds effectively with the concrete but will also withstand the wear and tear of daily life and thus, provide long-lasting protection. It is crucial to follow the recommended curing time before subjecting the floor to regular use.

Hazards To Avoid When Painting Concrete Floors

Applying sealer too thin

When applying too thinly, often when persons are trying to cover an area as cheaply as possible, remember that you will have next to no penetration and the final coating will be very weak.  The longevity of even an expensive paint when applied to thinly will be hugely reduced!

Applying sealer too thick

The top two reasons why you should not apply too thickly:

1) If it is a water or solvent based product, and it is applied in a very thick coat, the top surface of the coating will begin to ‘skin’ over and thus the curing begins.  However, the water (or solvent) this is within the coating itself then has to percolate through the surface skin in order for it too, to cure. This the overall curing time of the paint will be exponentially longer.

2) Applying any top coat too thickly may well result in the floor looking patchy rather than leaving a nice even finish.

Use of chemicals

No matter whether you use basic cleaning chemicals or the possibility of more harsh chemicals spilling onto the floor, make sure the coating has the fully cured before being exposed to chemicals.

Water, Condensation, Dew Point.

It is best to allow the coating to cure for at least 24 hours before being subjected to water allow.

High humidity levels and/or condensation dripping down onto the concrete floor can cause an uncured sealer to ‘bloom’ thus causing an unsightly whiteness to the surface.  This discolouration does not normally have too much of an ill-effect and will, in many cases, actually ‘wear off’ over a period of time.  However, if the coating is subjected to too much surface water, and in the worst case scenario, this can result in a poor or even non-cure situation.

Mixing and Pot-Life

If you have decided to use a twin pack resin sealer to paint your concrete floors, make certain that the product is mixed in the correct proportions. as stated on the data sheet.

Mixed materials will then have a pot life that can be anywhere from 5 minutes to 2 hours.  The pot life is the period of time you have to apply before the coating goes too hard and is mostly dictated by the curing time of the said product.  The faster the curing time, the shorter the pot life. Please consult with the manufacturer’s product data sheets BEFORE mixing.

Finally, and for obvious reasons, don’t mix more material than what you can apply within the given (pot-life) time.

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Factors to Consider When Choosing a Concrete Floor Sealer

Polycote Easi-Screed Flexible has proven to be the No. 1 choice for property owners, architects, and construction companies alike, due to its high thermal conductivity from the underfloor heating pipes, which has been shown to be around five times more effective than traditional screeds.

Professionally formulated with self-compacting properties, the liquid screed completely covers the underfloor heating pipework, eliminating air voids to ensure optimal heat transfer. It can be installed at much thinner depths compared to traditional sand and cement, providing ultimate control of the underfloor heating system. Energy usage and costs are greatly decreased when over-screeded with Easi-Screed Flexible, due to the system’s increased efficiency.

Easi-Screed Flexible has incredibly high strength and durability (with a compressive strength of 35N/mm²) together with low shrink characteristics. This allows the screed to be installed at far less thickness than traditional screeds, requiring a minimum of only 20mm cover to underfloor heating pipework. This therefore ensures far better heating performance, and faster heat transfer.  It is perfect for use with ground source and air source heat pumps, allowing lower flow temperatures, reduced energy consumption, CO2 emissions, and heating costs, as well as quick heating and cooling for greater system control.

The thermal conductivity of typical building materials can be measured according to standards such as BS EN 12664, BS EN 12667, and BS EN 12939. In comparison to electric-based systems, hydronic systems containing water and antifreeze offer both heating and cooling operations. Being a highly conductive thermally, this self-compacting anhydrite screed provides improvements over conventional screed or slab construction systems by reducing reaction time and enhancing thermal energy transfer.

Depending upon the method of construction, the thermal conductivity of the Easi-Screed system has been measured at between 2.2W/mK, and 2.9W/mK, therefore making it extremely responsive to underfloor heating. The lower thickness of the screed and high thermal conductivity, contribute to improved performance and substantially reduced response time for the entire system.

Easi-Screed Flexible has also been professionally formulated to be compatible for use with almost any underfloor heating system, including both conventional and renewable technologies. The strength, durability, and low shrink characteristics of the screed enables reduced depths without compromising performance and is suitable for most modern construction methods and substrates, subject to suitable engineering. The flowing and self-compacting nature of Easi-Screed Flexible, combined with its unique minimum depth capabilities, have enabled significant gains in placement time. Our contractors are now able to install up to an incredible 2000m² in just one working day. Compared with the limitations of traditional sand cement screeds, this is a massive saving in labour costs and downtime.

Furthermore, whilst on the subject of cost savings and speed, Polycote Easi-Screed allows for faster installation of final floor coverings as opposed to calcium sulfate screeds, which require a final moisture content of 0.5%, potentially delaying floor finishing by months. Easi-Screed can be tiled at a final moisture content of 5% and timber floors can be installed at a final moisture content of 2.8%, thereby expediting the entire build process with far less installation and curing times.

The complete range of Polycote Easi-Screed products are suitable for almost any type of floor covering, from tiles, terrazzo, wood, epoxy and polyurethane coatings and screeds, carpets, and vinyl flooring…, to name but a few!

Finally, Polycote Easi-Screed offers huge environmental benefits, by using far less of earth’s natural resources due to thinner application depths over against those required by conventional screeds. A win-win solution.

Related articles

What is a floor screed?

Types of floor screed.

Polycote UK would like to take the opportunity to thank you for taking an interest in these product and application articles and hope they have been some help to you.

We would of course be pleased to answer any specific questions should you wish to contact us directly on 01234 846400 or email: help@polycote.com

 

When installing floor screeds in poor weather, damp conditions and/or during periods of low temperatures, it is important that adequate precautions and protection measures are taken to ensure a successful installation of a new screed.

First and foremost, we advise that you read and fully understand the manufacturers data sheet that should clearly show the recommended application temperatures.

Cold Weather / Low Temperatures

As a general rule, the colder the temperature, the longer the curing time will be.  However, if the temperature drops too low, then this will affect the curing time so much that it could lead to a poor or even non-cure situation.  Indeed, if the uncured material is affected by frost / freezing conditions, the screed will not cure and will have to be removed and new material re-laid.

If the area to be laid is in an unheated warehouse, or maybe in what is an unused/empty building, the area should be heated up with space heaters or similar to a suitable temperature, somewhere between 10°C and 20°C.  Remember, if you are using space heaters, hot air rises and whilst it may indeed seem warn, the floor itself can take a lot longer for its temperature to rise, so it is well worth turning the heat on in the area well in advance of the day of installation, in order for the fabric (and specifically the floor) to ‘warm up’.  Don’t forget, the temperature of a concrete floor is hugely influenced by the ground temperature externally.

Once the floor is laid, ensure the building stays at the minimum temperature for the duration of the curing process.

Other specific areas of concern are where the external perimeter of the floor meets with an external wall.  Again, such areas can remain at a lower temperature due to cold penetration from outside.

Finally, doorways are another area that need to be considered, particularly industrial doors.  Cold draughts able to penetrate under such doors can also seriously affect the curing process.  Some people choose to sandbag or simply tape up along the bottom of the doors to help prevent such draughts.  Other considerations are if the doors cannot be fully closed due to the screed passing directly below.  In such circumstances, some people will lay cloths or some form of insulation material along the outside of the doors to help fill the gap and thus prevent unwanted draughts.

Wet Weather

It is vitally important that the newly laid uncured screed is not allowed to get wet before it has fully cured.  Equally, the underlying substrate must not be too wet in order to be able to lay a screed on top.  Such areas are best allowed to dry prior to the application of a screed.  Again, refer to manufacturers data sheets and guidelines on such matters and if still in doubt, ring the manufacturer and speak to a qualified person.

Similarly, to what has already be touched on in the Cold Weather Low Temperature section above, take note of the seal under doorways and ensure they are watertight.  Again, sandbag, tape or cover any such gaps with some form of waterproof material as damp/water penetrating onto an uncured screed with cause a poor or non-cure situation.

Roof leaks should obviously be repaired and sealed prior to the laying of any new screed in case of unwanted rain, as should any machinery or pipework leaks.

What can affect curing times?

The curing period of a new screed is hugely dependent upon the atmospheric temperature together with the existing floor substrate temperature.  The colder the temperature, the longer the material will take to cure.

Equally, the humidity levels can hugely affect the ultimate curing and hardness of the new screed.  Remember, water is added to the screed and this needs to be able to evaporate during the curing process.  If the weather is inclement and/or the air is saturated with water due (mainly) to recent rainfall and low temperatures, the water within the new screed will be unable to dissipate into the already ‘waterlogged’ atmosphere and thus, this can greatly extend the curing process.

Good airflow through a building is always a good way of helping to dissipate evaporating water as a very hot, airtight area can have an equal effect of the room sweating and thus preventing the water from escaping from the screed.

Transportation and Storage

Water will affect the properties of both cement and aggregates. Therefore, it is vitally important that all materials are stored in dry locations and protected from moisture and rainwater.

It is worth noting that screeds, particularly self-levelling floor screeds have been formulated to have a specific amount of water to be added to allow both the product to be able to be laid, to be able to initially cure and to be able to harden to the strengths as proven in prior testing.  If materials are allowed to take in water or dampness prior to the mixing process, this will affect all of the above-mentioned points, where it be the pourability of the and curing of the material.  Finally, and as a result of too much water within the mix, this then impacts the ultimate strength/hardness of the cured material which will reduce the usability / longevity of the finished floor surface.  All for the sake of not taking a bit of care!

But we’d like to finish on a good note so our final advice is; look after the materials and they will look after you!

Related articles

Checklist For Self Levelling Floor Screed

Types of floor screed.

Polycote UK would like to take the opportunity to thank you for taking an interest in these product and application articles and hope they have been some help to you.

We would of course be pleased to answer any specific questions should you wish to contact us directly on 01234 846400 or email: help@polycote.com

Choosing the right floor screed system might seem complex but with a little help and guidance afforded from this simple checklist, we feel you will be well on the way to making some better and more informed decisions to assist with your project.

Of course, we would welcome you to contact one of our team, who will happily establish exactly what your circumstances and requirements are and be able to answer any of your questions or concerns. We will be able to tell you exactly what product to use and the reason and justification for the said product.

However, for your initial perusal we hope you find the following information useful.

1. Screed Specification

There are a huge variety screeds now available, so the most important check is to make sure the screed in question is suitable for your requirements:

1. Strength (Normally shown as N/mm)
2. Minimum thickness
3. Maximum thickness
4. Pot life
5. Curing times
6. Minimum application temperatures
7. Maximum application temperatures
8. Flexural strength (where relevant)

Further helpful advice can be found in the British Standards information documents; BS8204 and BS800

2. Inspection of Existing Floor Structure

It is vitally important to inspect the exiting screed thoroughly prior to the application of any screed.  Please note: the suggested remedy for each point will be outlined later in this document.

1. Check the condition and soundness of the existing surface.
2. Check for any evidence of structural cracks.
3. Check thoroughly for any evidence of damp.
4. Check thoroughly for any evidence of oil contamination.
5. Check the levels of the floor to ascertain the high and low points.
6. Check for existing expansion joints and mark their exact locations prior to the layman of any screed.
7. Establish whether any part of the floor has underfloor heating.
8. Is the floor area to be screeded internal (within an enclosed building) or external (open to the elements)?

3. Base Preparation

Condition and soundness of the existing surface

The existing surface should be thoroughly cleaned and ‘keyed’ to ensure a perfect adhesion between the new screed material and the existing concrete slab.  It is vitally important to remove all loose/friable material including any existing floor paint or sealer.

Preparation can be carried out chemically with the use of an acid etching material (Polycote Etch It), or mechanically with the use of diamond floor grinders, scabblers and/or shot blasters.  It is highly advised that you use a machine connected to a dust recovery unit / industrial vacuum to ensure the entire area is not filled with dust.

Structural cracks

If your floor is suffering from structural cracking, it is highly advisable to establish why the cracking of the concrete has occurred. This could be for several reasons, a) the most common reason being not enough or indeed no expansion joints, b) expansion joints that are no longer functional due to the build-up of dirt within the joint c) the joint has been incorrectly filled in with an inert, solid (repair) material thereby preventing the screed from being able to expand or contract, d) the screed being subjected to too much weight or c) subjected to too much vibration, often caused by heavy machinery.

Obviously, there is little the user can do about the weight or movement of machinery but, if it is simply an issue with the expansion joints, this can be easily rectified by cleaning/re-cutting the joint and filling with a Polycote Jointex expansion product specifically formulated to allow for expansion and contraction.

With regard to any structural cracks, it is advised to both clean and dry out the crack as much as possible and fill with Polycote Crackfiller EP100, an ultra-low viscosity pure epoxy resin.

Rising Damp

If any rising damp has been identified, the floor must be coated with a twin pack epoxy Damp Proof Membrane (Polycote DPM Primer), to provide a totally waterproof barrier and thus prevent the rising damp from pushing up through the new floor screed.

Oil Contamination

If oil contamination has been identified, it is important that all surface contamination is removed as much as possible using Polycote Degrease IT.  Once the surface is clean, paint the floor with Polycote OT Primer in order to totally seal the surface and prevent the oil from rising up through the new screed.

 Further Note:  Re. Damp and Oil

When applying either the OT Primer or the DPM Primer prior to the installation of a screed, it is recommended that two coats are applied.  The first coat should be applied and allowed to cure, prior to a second coat being applied at right angled to the first.  Whilst the second coat is still wet, kiln dried quartz aggregate should be sprinkled on to the wet primer.  All excess aggregate may be removed the following day and prior to the installation of the self-levelling floor screed (Polycote Easi-Screed).

High and Low Points – What is best to do?

This is often an interesting consideration as to what is best to do. If you have a poorly laid concrete with a ‘few’ high spots that are causing an issue, it is worth contemplating whether just to grind the high spots down and not put a screed at all.  However, please bear in mind that for every 1sq.m x 1mm deep, you will be removing approximately 2kgs of concrete.  Whilst this might not sound much, now multiply the total area you have with the depth you wish to remove and multiply that by 2.  You will then know how many kilos you are going to have to move, and the skip(s) you will need to take the waste!

When allowing for the minimum thickness required for the chosen screed, make sure you allow this depth over the high spots and will then need to calculate how much material you will need in excess to fill in the lower areas, which in turn, will obviously be laid to a greater thickness.

If you are not sure how to calculate this, then please don’t hesitate to call the technical helpline 01234 846400, where one of the team will be more than happy to offer help and advice.

4. Expansion Joints

Expansion joints are a vital part of a successful and long-lasting concrete floor.  It is therefore important that you mark out on a plan exactly where they are so that the joints can then be reinstated by cutting through the new screed once it has cured.

Alternatively, rather than going by a written plan, a mark can be made on the wall denoting the starting/finishing points. Alternatively, some people simply use 6” nails that are driven into the joint.  This method is actually very helpful, especially when you have existing slabs where the joints are not in a nice straight line, or the joints are ‘dog-legged’ or simply not at 90°.  This way, the whole length of joint can be easily plotted and then as soon as the screed has cured sufficiently to walk on, the nails can be pulled out and will then clearly leave holes that will show the exact path of the original expansion joint below.

Please note it is very important the cutting through of the joints is done directly over the existing joint below.

Once cut, the open joint should then be filled with one of our Jointex range of products, to both protect the edges of the joint and to prevent the build-up of dirt in the joint.

5. Underfloor Heating

When screeding over an underfloor heating system, no matter whether it is a wet system or electric, you should use Easi-Screed Flexible. This has been formulated to reduce the risk of cracking due the extra expansion and contraction brought on by the greater fluctuations of direct heat.

6. Internal / External Applications

Easi-Screed Industrial, Easi-Screed Standard and Easi-Screed Flexible are all suitable for use internally, within a building.  However, if you have an external application, where the product will be subjected to the extremes of weathering, please us Easi-Screed External.

7. Mixing

Due to there being many and varied self-levelling compounds we can only advise that you read and fully understand the Manufacturers Material Data Sheet, prior to the mixing and/or application of any product.  Should you have any questions or concerns, contact the manufacturer before any commencement of works.

It is important that you have the entire area prepared and primed as necessary.  Fill a suitable clean mixing vessel with the required quantity of clean water as per the material data sheet.  Add the contents of the Easi-Screed (powder/aggregate) to the water whilst mixing and folding in with the mixing paddle.  It is highly advised to use a mixing paddle connected to a suitable drill as it is important that the product is mixed evenly, thoroughly, and as quickly as possible.

8. Pouring and Levelling

Pour the mixed material out onto the floor and spread out with a pin leveller. The length of the pins on the Pin Leveller should be set to the thickness of screed required. As soon as the screed has been spread out, the floor should be ‘spiked’ with the spiked roller to pop/disperse any air that has become entrapped in the screed whilst mixing.  Please note, it is both normal and inevitable that air bubbles become entrapped in the mixture, and it is therefore very important that the screed is spiked as soon as possible after laying, whilst it is still wet. This will also help the screed itself to level out and also help each poured mix to merge perfectly with its previously laid counterpart.

Please note:  It is extremely important to maintain a wet edge so that each pour blends in perfectly with the previous pour.

Spiked shoes are also available for the user to enable them to be able to walk over the wet screed during the pouring procedure.

7. Curing

The benefit of installing one of the Easi-Screed range of self-levelling screed system is speed.  Its fast to mix, fast to lay and fast to cure. So much so, that one of our teams of approved installers can lay up to 2000sq.m in just one day, which can then be traversed by vehicular traffic the very next day! Furthermore, Easi-Screed provides a high wear, smooth and dust free surface and can be laid as thin as 2mm.

8. Screed Protection

Ensure the new screed is protected during the curing process.  The temperature should not be allowed to drop below 10°C, space heaters are advised in the colder months.  Protect from foot traffic for a minimum of 3 hours and from pallet trucks and forklifts for 24 hours. Consult the manufacturer’s Material Data Sheet for specific requirements or ring our technical helpline for further advice.

9. Sealing the Surface

If the floor is likely to be subjected to liquids or if you would like to paint it for aesthetic reasons, it is highly advised to complete this exercise as soon as possible after laying and before any ‘major’ use.  It is far better to complete a coating before the screed has been able to absorb impurities into itself, whether it be oil or chemical spillages, from general dirt to rubber tyre marks.

For a clear sealer, Polycote Flortex PU is an excellent single pack polyurethane floor sealer.

Should you wish to achieve a colour, 2 coats of a twin pack water dispersed epoxy resin (Polycote Flortex SG) is one that can be applied after just 24 hours.

Finally, if you are looking for the best, then one coat of Polycote WD Primer followed by one coat of Polycote Flortex Professional, will give you the longest lasting high build coating, that is resistant to both chemical and heavy traffic.

Related articles

What is a floor screed?

Types of floor screed.

Polycote UK would like to take the opportunity to thank you for taking an interest in these product and application articles and hope they have been some help to you.

We would of course be pleased to answer any specific questions should you wish to contact us directly on 01234 846400 or email: help@polycote.com

 

 

Concrete is a widely used building material due to its strength and durability. However, it is not immune to cracks. Understanding the causes of concrete cracks is crucial to prevent structural issues and ensure the longevity of buildings and infrastructure. In this article, we will explore the six common causes for concrete cracks and discuss preventive measures to mitigate them.

Understanding the Nature of Concrete

Before considering the causes of concrete cracks, it is essential to grasp the composition and characteristics of concrete and the understanding of the composition and properties of concrete is crucial in ensuring its long-term durability and structural integrity.

Having been used for centuries as a reliable and versatile construction material, the mixture of cement, water and aggregate gains strength over time through a process called hydration, where the cement particles react with water to form a solid mass. Its ability to withstand heavy loads and resist weathering makes it a popular choice for various applications, from building foundations to road pavements.

The Composition of Concrete

The composition of concrete plays a significant role in its strength and integrity. The proportion of cement to water affects the hydration process. Insufficient water can lead to inadequate hydration, resulting in weaker concrete prone to cracking. On the other hand, excessive water can cause shrinkage and reduce durability.

In addition to cement and water, aggregates such as sand and gravel are added to the concrete mixture. These aggregates provide bulk to the concrete and contribute to its overall strength. The size and shape of the aggregates can also affect the workability of the concrete, making it easier or more difficult to place and compact.

Furthermore, chemical additives and fibres can be incorporated into the concrete mix to enhance specific properties such as:

1) Plasticizers: formulated to improve workability, making the concrete more fluid and easier to pour.

2) Air-entraining agents; to create tiny air bubbles in the concrete, which increases the concretes resistance to freeze-thaw cycles.

3) Frost inhibitors: help support the curing of the concrete where conditions are colder than the required limits for ‘standard’ concrete mixes. extra fast curing agents. These can be added to a concrete mix where time constraints require a faster back-to-work time.

4) When added to the concrete mix, specialist fibres can provide added strength to the concrete as well as improving resistance to cracking.

The Durability and Strength of Concrete

Concrete’s durability and strength are influenced by factors such as the quality of the materials used, the curing process, and the mix design. Poor-quality materials or improper mixing procedures can compromise the structural integrity of concrete, making it susceptible to cracks.

During the curing process, the concrete needs to be protected from excessive moisture loss. This can be achieved by covering the concrete with plastic sheets or applying a curing compound. Proper curing allows the concrete to develop its full strength and reduces the likelihood of cracking.

Moreover, the mix design of concrete is crucial in determining its strength and durability. The ratio of cement to aggregates, as well as the type and proportion of additives, can significantly impact the performance of the concrete. Engineers carefully design concrete mixes to meet specific project requirements, considering factors such as load-bearing capacity, exposure conditions, and desired lifespan.

It is also worth noting that the curing time of concrete plays a role in its ultimate strength. While concrete gains strength rapidly in the first few days, it continues to harden and develop strength over an extended period. This is why construction projects often specify a minimum curing time before subjecting the concrete to heavy loads or other stressors.

In conclusion, understanding the composition and characteristics of concrete is essential in ensuring its long-term durability and structural integrity. The proportion of cement to water, the quality of materials, the curing process, and the mix design all contribute to the strength and performance of concrete. By paying attention to these factors, engineers and builders can create concrete structures that stand the test of time.

The Impact of Environmental Factors on Concrete

Concrete is a widely used construction material due to its strength and durability. However, it is not impervious to the effects of the environment. Environmental factors play a significant role in the deterioration of concrete, affecting its longevity and structural integrity. Two of the most common culprits behind concrete cracking are temperature fluctuations and moisture.

Temperature Fluctuations and Concrete Cracks

Concrete is known to expand when exposed to high temperatures and contract under freezing conditions. These temperature fluctuations can create significant stresses within the concrete, leading to cracks over time. Imagine a scorching summer day, with the sun beating down on a concrete structure. As the temperature rises, the concrete expands, trying to accommodate the increased thermal energy. However, when the temperature drops during the cool night, the concrete contracts. These repeated cycles of expansion and contraction can weaken the concrete’s structural integrity, making it more prone to cracking.

In addition to the regular expansion and contraction, rapid temperature changes can cause a phenomenon known as thermal shock. Imagine a sudden downpour after a scorching day. The rainwater, being cooler than the concrete, causes rapid cooling. This sudden temperature change can create stress within the concrete, leading to cracks. Thermal shock can also occur during winter, when concrete structures are exposed to freezing temperatures after being heated by the sun during the day.

The Role of Moisture in Concrete Deterioration

Moisture is another critical environmental factor that affects concrete. When water enters the concrete, it can react with the cement, leading to expansion and subsequent cracking. This process is known as the alkali-silica reaction, where the alkalis in the cement react with the silica present in the aggregates, forming a gel-like substance. As this gel expands, it exerts pressure on the surrounding concrete, causing cracks to develop.

Moreover, moisture can corrode the reinforcing steel within the concrete. Reinforced concrete relies on steel bars or mesh to provide additional strength. When moisture penetrates the concrete and reaches the steel, it can initiate a process called corrosion. Corrosion weakens the steel, compromising its ability to provide reinforcement and support to the concrete. This not only affects the structural integrity of the concrete but also reduces its load-bearing capacity.

Furthermore, moisture can also lead to the growth of Mold and mildew on the concrete surface. These organic growths not only make the concrete aesthetically unappealing but can also contribute to its deterioration. The presence of Mold and mildew can accelerate the breakdown of the concrete’s surface, making it more susceptible to cracking and erosion.

Considering the significant impact of temperature fluctuations and moisture on concrete, it is crucial to take preventive measures during the construction phase. Properly designed concrete mixtures, incorporating materials that can mitigate the effects of temperature changes and moisture, can significantly enhance the durability and longevity of concrete structures. Additionally, regular maintenance and inspection can help identify early signs of deterioration, allowing for timely repairs and preservation of the concrete’s integrity.

The Influence of Poor Construction Practices

Inadequate construction practices can have a detrimental effect on the quality of concrete. Two common factors contributing to cracks are inadequate concrete mixing procedures and improper curing.

Inadequate Concrete Mixing Procedures

Improper mixing of concrete ingredients can result in weak spots within the structure, making it susceptible to cracks. Insufficient mixing or uneven distribution of aggregate and cement can lead to a lack of homogeneity, compromising the overall strength of the concrete.

The Consequences of Improper Curing

Curing is a crucial step in the concrete curing process that ensures optimal hydration and strength development. When concrete is not properly cured, it can dry too quickly, leading to shrinkage and cracking. Insufficient curing time or exposure to adverse weather conditions can also hinder the curing process.

Lack of expansion joints

A concrete expansion joint is a gap which allows the concrete to expand and contract as the temperature increases or decreases respective, thereby allowing movement of the floor and reducing the stresses which are the major cause of cracking.

Concrete expansion joints are particularly important where separate pours of concrete are required. An expansion gap should always be provided as these ‘separate’ slabs will always be subjected to differing movement and vibrations caused by caused by traffic and/or machinery. Furthermore, an expansion joint (gap) should also be created between the floor and wall transitions as well as where there are differing materials (ie. metal inspection covers) where each material type has their own expansion and contraction characteristics.

It is always advisable to consult a structural engineer who will ensure the floor or structure has a sufficient quantity and size or expansion joint. However, for the purposes of this article here are some points for as a ‘general guide’ for your consideration:

1) Expansion joints should be incorporated into slabs with a surface area exceeding 6sq.m.

2) Expansion joints should be placed around 30 times the slab thickness apart.

Therefore, for a slab which is 100mm (0.1m) thick, the joints should ideally be placed around 3m apart.

3) When cutting expansion joints into previously poured and cured concrete, it is advised that the joints should be cut down to around a quarter of the thickness of the slab. So, for example, for a 100mm thick slab, the joints would be cut to approximately 25mm deep.  However, for thicker slabs (over 100mm thick), ensure that the cut joints are at least 25mm deep.

The Role of Excessive Load and Structural Stress

Concrete is designed to bear loads and provide structural support. However, excessive loads and structural stress can lead to cracks and compromise its strength.

Understanding Load-Bearing Capacity of Concrete

Each type of concrete has a specified load-bearing capacity. When this capacity is exceeded, cracks can occur. Determining the appropriate grade of concrete based on the expected load is crucial to ensure structural stability and prevent cracks.

How Structural Stress Leads to Cracks

Structural stress can arise from various factors, including improper design, settlement, and vibrations. When the applied stress exceeds the concrete’s ability to resist, cracks can develop. It is essential to consider all potential stressors during the design and construction phases to prevent future cracking.

The Effect of Shrinkage on Concrete Cracks

Concrete undergoes shrinkage as it dries and hardens. This natural process contributes to the formation of cracks if not adequately controlled.

The Science Behind Concrete Shrinkage

Shrinkage occurs due to the evaporation of excess water from the concrete. As the water evaporates, the volume of the concrete reduces, causing it to shrink. This shrinkage can result in cracking if not properly managed.

Preventing Shrinkage-Induced Cracks

To prevent shrinkage-induced cracks, various strategies can be employed. The use of shrinkage-compensating admixtures, joint spacing, and reinforcement techniques can help mitigate the negative effects of shrinkage and minimize cracking.

In conclusion, concrete cracks can arise from a combination of factors, including inadequate composition, environmental influences, construction practices, excessive loads, and shrinkage. Understanding these causes is essential in preventing structural issues and maintaining the durability of concrete structures. By adhering to proper construction techniques, considering environmental factors, and implementing preventive measures, we can ensure that concrete remains strong, durable, and crack-free for years to come.

Related articles

How to Repair a Damaged Concrete Floor

How to Repair a Concrete Floor

Polycote UK would like to take the opportunity to thank you for taking an interest in these product and application articles and hope they have been some help to you.

We would of course be pleased to answer any specific questions should you wish to contact us directly on 01234 846400 or email: help@polycote.com

A clean and well-maintained factory floor is essential for every manufacturing business. Not only does it contribute to the overall efficiency of the operations, but it also plays a crucial role in ensuring the safety of the workers. In this article, we will explore the importance of having a well-painted factory floor and how it can benefit your business. We will also discuss the factors to consider when choosing the right paint for your factory floor and provide a step-by-step guide for painting and maintaining it.

Understanding the Importance of a Well-Maintained Factory Floor

The factory floor serves as the foundation for the entire manufacturing process. Its condition significantly impacts the efficiency and smooth flow of operations. A well-maintained factory floor provides a sturdy and level surface, ensuring that heavy machinery and equipment can be safely operated without any disruptions or accidents.

Furthermore, a clean and organized factory floor improves productivity by reducing the risk of inefficiencies, such as misplaced materials or obstacles. It allows workers to navigate the workspace with ease, saving time and effort.

When it comes to maintaining a factory floor, attention to detail is key. Regular inspections should be carried out to identify any signs of wear and tear. This includes checking for cracks, uneven surfaces, or worn-out markings. Addressing these issues promptly not only prevents accidents but also extends the lifespan of the factory floor.

In addition to inspections, regular cleaning is essential to keep the factory floor in optimal condition. Dust, debris, and spills can accumulate over time, causing potential hazards. By implementing a thorough cleaning routine, including sweeping, mopping, and removing any obstructions, the factory floor remains clean and safe for workers to operate on.

Operational Efficiency

The factory floor acts as a crucial component in maintaining operational efficiency. By providing a well-organized and optimized space, it enables workers to move efficiently between different workstations. This reduces the time taken to complete tasks and enhances overall productivity.

Efficient workflow is not just about the layout of the factory floor but also the design and placement of equipment. A well-thought-out floor plan ensures that machinery and workstations are strategically positioned, minimizing unnecessary movement and optimizing production processes.

Furthermore, the factory floor can be enhanced with the use of technology. Implementing automated systems, such as conveyor belts or robotic arms, can streamline manufacturing processes and reduce manual labour. This not only improves efficiency but also frees up workers to focus on more complex tasks that require human expertise.

Enhancing Visibility and Safety with Floor Paint

Using floor paint can significantly improve visibility in the workplace. By painting designated walkways, hazard areas, and emergency exits, you can provide clear guidance to workers, reducing the risk of accidents and promoting a safer environment.

Furthermore, the use of contrasting colours can also help differentiate between different zones, making it easier for employees to determine where they should be at any given time. This not only enhances safety but also improves efficiency by streamlining movement within the factory.

Where every walkway is clearly marked with colour, whether it be bright, vibrant colours or maybe your company corporate colour, you can transform your factory into a well-organized and visually appealing workspace.

Durability and Longevity: The Long-Term Advantages

High-quality floor paint is designed to withstand the heavy foot traffic, machinery, and chemicals commonly found in factory settings. Applying a durable paint coating creates a protective barrier that prevents the floor from deteriorating, extending its lifespan and reducing maintenance costs over time.

Factory floors endure all manner of stresses and strain, including flexural strain by constant movement, often the cause of structural cracks, impact damage and chemical attack, as well as wear and tear caused by machinery and heavy traffic. Without proper protection, floors quickly wear, and this leads unwanted cost, not only for the materials and labour, but also the disruption and downtime to your operation whilst the repair works are being carried out. By investing in a good quality floor paint, you can ensure your factory floor remains in top condition for a far longer period of time

To seal the floor not only prevents the substrate from becoming stained and contaminated from oil and chemicals but, due to the fact that they are sealed, this greatly reduces the daily cleaning times and thus, saves time, effort and money on a daily basis.

Aesthetic Appeal and Its Impact on Worker Morale

While the functionality and safety aspects of a factory floor are crucial, the aesthetic appeal needs to be seriously considered. A clean and visually appealing workplace can have a positive impact on employee morale and motivation.

It is well known that a factory with a dull, uninspiring floor do not help to create a sense of excitement or pride. However, by investing in a good quality floor paint, this not only enhances the overall look of the factory floor but more importantly, you create an environment that employees are proud to work in, and boost their sense of belonging, mental well-being and ultimately, productivity.

Studies have shown that a visually appealing workspace improves employee satisfaction and engagement. When employees feel proud of their workplace, fostering a positive work culture where they are much more likely to take ownership of their tasks as well as striving far harder, for excellence.

Safety Implications of a Neglected Factory Floor

A neglected factory floor poses serious safety risks for both workers and equipment. Uneven surfaces, cracks, or worn-out markings can cause accidents, leading to injuries or damage to machinery. These incidents not only disrupt production but can also result in costly lawsuits and medical expenses.

Regular maintenance and painting of the factory floor can help identify and rectify potential hazards, ensuring a safer working environment for employees. In addition to visual inspections, it is important to conduct regular tests to assess the structural integrity of the floor. This may involve checking for load-bearing capacity and conducting non-destructive testing to detect any hidden defects.

Moreover, proper safety protocols should be established and communicated to all workers. This includes wearing appropriate personal protective equipment (PPE) and receiving training on how to operate machinery safely. By prioritizing safety and maintaining a well-kept factory floor, businesses can reduce the risk of accidents and create a culture of workplace safety.

In Conclusion

In conclusion, the painting of your factory floor offers numerous benefits and is clearly a worthwhile investment.

For every factory owner. It will:

1. enhance visibility
2. answer all HSE requirements
3. increase durability
4. extend longevity
5. remove potential hazards
6. promote good company culture
7. save the frustrations and disruptions caused by downtime, and as a result…
8. …. increase punctuality and profitability.

For your employees, a well painted, safe and attractive floor will:

1. transform the working environment
2. boost worker morale
3. improve mental health
4. improve cleanliness
5. improve health and safety
6. reduce accidents
7. reduce maintenance downtime
8. show respect for your employees and their environs
9. strengthen good culture
10. increase productivity
11. increase profits

As for visitors, whether they be customers or suppliers, a clean and well-presented factory will:

1. promote a positive atmosphere
2. help present your product or service in the best possible way
3. show respect and appreciation to your visitors
4. show recognition of your care and comfort of your staff
5. help transmit the enthusiasm and positivity of your staff to the customer
6. give the customer or supplier confidence that this is an organised, respectable and trustworthy company.

Related articles

Choosing the Right Paint for Your Factory Floor

What is the best industrial floor paint to use?

Factors to Consider When Choosing a Concrete Floor Sealer

A Comprehensive Guide to Different Types of Concrete Floor Sealers

So why wait? Transform your floors and working environments today and reap the rewards that extend far beyond simple aesthetics. If you are genuinely looking for a long term solution, then ring Polycote now on 01234 846400 and speak to one or our advisors who, very simply, can tell you exactly WHAT you should use and WHY!

 

 

 

 

 

 

Floor screeds are applied over a concrete or asphalt base to provide a smooth and level surface for the final flooring system. Polycote have various types of floor screeds available, each designed to serve a specific purpose and with its unique set of benefits.

Understanding Floor Screed

Definition and Purpose

A floor screed is a mixture of cement, sand, and water that is poured or troweled onto a concrete or asphalt subfloor and is an essential component of any construction project.  The floor screed provides a solid foundation with a hard wearing surface as well as ensuring the smooth surface needed for final flooring finishes.

The primary purpose of floor screed is to create a level and stable surface, which will not only support the final flooring system, but also provide additional benefits such as insulation and moisture resistance. A well-laid floor screed can help to improve the overall energy efficiency of a building by reducing heat loss through the floor. Additionally, it can help to prevent dampness and moisture from seeping into the building, which can cause structural damage over time.

Types of Floor Screed

There are several types of floor screed available in the market, each with its own unique set of properties and benefits. The most common types of floor screed include:

• Traditional cement sand screed
• Liquid screed
• Fast-drying screed
• Fiber-reinforced screed
• Polymer-modified screed

Traditional Cement Sand Screed

The most commonly used type of floor screed is the traditional cement sand screed. It is made up of a mixture of cement, sand, and water. The curing time of a tradition screeds are approximately 2-4 weeks to dry completely.  However, this is length of time is strongly influence by three main factors; the thickness of the screed laid, the atmospheric temperature and humidity levels.

Traditional cement sand screed are cost-effectiveness and typically laid to a depth of 50mm to 75mm. However, they can easily be laid to a thickness of up to 100mm making it ideal for uneven or sloping floors as well as providing excellent thermal conductivity when used in the covering of underfloor heating systems.

Liquid Screed

Liquid screeds such as Polycote Easiscreed offer a huge advantage over traditional screed.  They are made up of a liquid polymer binder mixed with cement and other additives to create a flowing mix that can be laid to a laser level finish with faster and more efficient results. It can be laid at any thickness from 2mm to 50mm in one pour and is therefore the ideal choice for smoothing out rough, worn, and uneven concrete.

Requiring no specialist labour or equipment, other than a mixing paddle (fixed to a standard drill), a spiked roller to disperse any air bubbles within the mix and a pin-leveller to ensure the screed is laid to a consistent thickness, the mixed product can be poured onto the existing surface whereby it will flow out and create a smooth, non-dusting finish.

Commonly referred to as a ‘pumped screed’, Easiscreed can be laid at a rate of as much as 2000sq.m in one day and together with its extremely fast curing properties, which means it can accept forklift traffic after only 24 hours this ensures it remains the first choice for all industry and contractors alike.

Polycote Easiscreed also provides excellent thermal conductivity, making it ideal for use with underfloor heating systems.

Fast-Drying Screed

For projects with tight deadlines, fast-drying screed is the ideal choice. This type of screed contains additives that accelerate the drying process and can be ready for the final flooring system in as little as 24 hours.

Fast-drying screed is perfect for projects that require a quick turnaround time, such as commercial buildings or public spaces. It is also suitable for use with underfloor heating systems, providing excellent thermal conductivity and ensuring efficient heat distribution throughout the building.

Fibre-Reinforced Screed

Fibre-reinforced screed includes additional fibres such as glass or polypropylene, which help to improve the screed’s strength and durability. It is ideal for areas with heavy traffic or where the floor needs to withstand significant wear and tear.

Fibre-reinforced screed is a popular choice for industrial buildings, warehouses, and car parks. It can also be used in residential buildings, providing a durable and long-lasting finish that can withstand the demands of everyday life.

Polymer-Modified Screed

Polymer-modified screed includes synthetic resins, which enhance the mix’s properties such as strength, flexibility, and durability. It is suitable for use in areas with high humidity or where there is a risk of moisture damage.

Polymer-modified screed is perfect for use in bathrooms, kitchens, and other high-moisture areas. It provides a waterproof barrier that protects the underlying structure from moisture damage, ensuring a long-lasting and reliable finish.

In conclusion, choosing the right type of floor screed is critical to ensure a reliable and durable finish that meets your specific project requirements. Whether you opt for traditional cement sand screed, liquid screed, fast-drying screed, fibre-reinforced screed, or polymer-modified screed, each type has its unique set of properties and benefits that can help you achieve the perfect finish for your building.

Benefits of Using Floor Screed

When it comes to flooring, the importance of a level and flat surface cannot be overstated. A perfectly level floor is not only visually appealing, but it also makes the installation of the final flooring system much easier.

Improved Leveling and Flatness

The primary benefit of using floor screed is that it helps to create a perfectly level and flat surface which is essential for many applications, from the installation of machinery and equipment through to the installation of complete racking systems. In warehouses and factories, a level floor is crucial, not only for the safe movement of heavy machinery and equipment, but also for the safety of personally by reducing slip and trip hazards.

Enhanced Thermal and Acoustic Insulation

Depending on the type of floor screed being used, it can also provide additional benefits such as thermal and acoustic insulation. This means that the final flooring system will be more energy-efficient, as it will retain heat better, and also be quieter, thanks to the sound-absorbing properties of the screed.

Thermal insulation is particularly important in colder climates, where it can help to reduce heating costs and improve energy efficiency. Acoustic insulation, on the other hand, is essential in environments where noise levels need to be controlled, such as schools, hospitals, and offices.

Increased Load-Bearing Capacity

Another significant advantage of using floor screed is that it can increase the load-bearing capacity of the concrete subfloor. This means that it can support heavier loads, which is especially important for commercial and industrial applications.

For example, in warehouses and factories, heavy machinery and equipment are often used, and a strong and sturdy floor is necessary to support their weight. Similarly, in car parks and garages, the floor must be able to withstand the weight of multiple vehicles.

Moisture Control and Damp Resistance

Finally, floor screed can also help to control moisture and prevent damp from seeping through the concrete subfloor. This is achieved by adding special additives such as Polycote Bondex to the mix that make it more resistant to water.

Moisture and damp can cause significant damage to buildings, and it is essential to take preventative measures to avoid any issues. By using floor screed, you can ensure that your flooring system is protected from moisture and damp, making it more durable and long-lasting.

Key considerations to ensure the right screed for your project

When selecting the right floor screed for your project, here are some important points for your consideration:

The amount of downtime that you can allow for the chosen screed to cure.

Whether the existing surface/screed needs to be removed

Any other considerations / influencing factors such as rising damp or surface contamination, such as oil, etc that could affect the adhesion of the new screed.

The thickness of screed required.

The type and amount of traffic / wear and tear that the screed will be subjected to.

The type of final flooring system to installed over the screed, whether if be paint, vinyl, carpet, wood, etc.

The level of insulation required.

These are just a few of the main considerations for your help.  However, Polycote are just a phone call away.  Ring us now and our trained advisors (who are mostly ex contractors with years of practical experience) can quickly and easily help guide you to the RIGHT type of floor screed for YOUR needs and ensure it is installed to the highest standards.

Related Articles

Types of Floor Screed

How to Screed a Floor Using Sand Cement Screed.

Polycote UK would like to take the opportunity to thank you for taking an interest in these product and application articles and hope they have been some help to you.

We would of course be pleased to answer any specific questions should you wish to contact us directly on 01234 846400 or email: help@polycote.com

 

There are several types of floor screeds you can use to achieve a well-screeded floor. The choice of the screed will depend on various factors such as the type of subfloor, the intended use of the floor, and the thickness of the screed required.

The four most common types of floor screeding material are:

• Cement Based Screed: This is the most common type of screed used in construction. It is made from a mixture of cement, sand, and water. It is ideal for use in areas with high traffic such as warehouses, factories, and car parks.
• Anhydrite Screed: This is a type of screed made from calcium sulphate. It is ideal for use in areas where a quick-drying screed is required. It is also suitable for use with underfloor heating systems.
• Calcium Sulphate Screed: This is a type of screed made from a mixture of calcium sulphate and sand. It is ideal for use in areas where a quick-drying screed is required. It is also suitable for use with underfloor heating systems.
• Self-Levelling Screed: This is a type of screed that is designed to level itself. It is ideal for use in areas where a smooth and level finish is required. It is also suitable for use with underfloor heating systems.

Self-Levelling Cementitious Floor Screeds

 

1) Industrial Grade Self Levelling Screed

Formulated primarily for the industrial and commercial sectors, screeds such as

Easi-Screed Industrial are one of the strongest self-levelling cementitious screeds on the market. They are also non-dusting and has extremely good flowability.  These products can be easily pumped and our contractors are able to installed up to 2000sq.m in just one day.

Furthermore, these screeds can be laid to a laser level finish where circumstances demand such accuracy.

2) ‘Standard’ Self-Levelling Cementitious Screeds

Formulated mainly for light industry and/or heavy domestic installations, these screeds may be laid as thin as only 2mm and up to 20mm in a single layer.  They are fast curing, non-dusting and will accept foot traffic after only 3-4 hours. Other floor coverings such as carpets may be laid after only 24 hours from placement of the screed.  Obviously, this is dependent upon the ambient temperature and atmospheric humidity levels.

3) Flexible Self-Levelling Screeds

Fast curing highly specialised self-levelling screed materials such as Easi-Screed Flexible have been professionally formulated for application over floors subject to movement or vibration and is ideal for the covering of underfloor heating systems.

They may be laid as this as 2mm and up to 50mm in a single layer. Should a thicker screed be required, the product can be laid in multiple layers. However, a minimum period of 24 hours should be allowed between each layer.

4) Self-Levelling Cementitious Screeds for External Use

The screeding and levelling of external concrete areas has long been a problem and many failures have been experienced by people using cementitious screeds unsuitable for external use.

It is therefore extremely important to take care when specifying self-levelling screeds for external uses.  Polycote UK have specifically formulated a product (Easi-Screed External) to withstand stresses caused by inclement weathering, whether it be hot or cold temperatures and/or wet or dry conditions.

Additional Helpful Information

With a view to helping the user to identify / specify the correct floor screed, this article has collated the following information from BS8204 and BS EN 13318:

Levelling screed – A screed suitably finished to obtain a defined level and to receive the final flooring. It does not contribute to the structural performance of the floor.

Wearing screed  – A screed that serves as flooring. This term was formerly known as high strength concrete topping. It is also used to refer to structural toppings as well as wearing surfaces.

Bonded Screed – A screed laid onto a mechanically prepared substrate with the intention of maximising potential bond.

Unbonded Screed – A screed intentionally separated from the substrate with the use of a membrane.

Floating Screed – A floor screed often laid on acoustic or thermal insulation.

Sand Cement Screed –A floor screed consisting of a screed material containing sharp sand and cement.

Fine Concrete Screed – A floor screed consisting of a concrete in which the maximum aggregate size is 10mm.

Related Articles

What is a Floor Screed?

How to Screed a Floor Using Sand Cement Screed

Checklist for self levelling floor screeds.

Polycote UK would like to take the opportunity to thank you for taking an interest in these product and application articles and hope they have been some help to you.

We would of course be pleased to answer any specific questions should you wish to contact us directly on 01234 846400 or email: help@polycote.com

 

Clearing the Space

The first step to preparing your garage floor for painting is to clear the space. Move any vehicles, bikes, or other items out of the garage. This will give you enough space to complete the painting process.

Whilst you can certainly paint the total area in stages, to paint a floor can be a very quick process and so it is much better if you can paint the whole area at the same time.  However, we are conscious that everything currently in the garage must go somewhere and if you do not have another storage unit or secure area, and don’t want to leave it ‘outside’, this might mean the painting has to be done in stages.

Cleaning the Surface

Any loose material such as dust and dirt must be removed from the surface.  Pay close attention to corners and edges, as these areas can often collect more dirt and debris.

Oil and any other contaminants must also be cleaned from the surface and Polycote Degrease IT is an excellent product to help remove such contamination. Degrease IT is designed to lift the oil from off the surface which must then be washed away with clean water and/or can be vacuumed up using a suitable aquavac machine.

It is best to allow the floor to dry as much as possible before applying the chosen coating.

Repairing Cracks and Holes

Before painting your garage floor, fill any cracks or holes in the concrete using an epoxy filler. Polycote has several floor repair products for this but for ease of explanation here we will mention just four:

1) Polycote Cretex EP.

Cretex EP is a twin pack epoxy floor repair that is extremely strong and will feather-edge to nothing, meaning that any shaped hole can be filled quickly and easily without having to cut out the concrete to a certain thickness.  This not only saves time and mess but also money!  Remember, the more concrete you remove, the more material you need to fill the now bigger hole!

2) Polycote Easifil

Easi-Fil is a fine filling paste that can be used to fill all those annoying chips, dips and holes caused by previous impact damage, worn or even poorly laid concrete.

3) Polycote Crackfiller EP100

Crackfiller EP100 is a 100% solids ultra-low viscosity resin professionally formulated to penetrate well into the cracks and complete solidify the concrete. The low viscosity means that it will even ‘pull down’ into hairline cracks as thin as 0.1mm. Should you have the unfortunate matter of a loose screed or topping, Crackfiller EP100 can even be used to re-adhere the topping to the substrate below.

4) Polycote Cretex OT Mortar.

Cretex OT Mortar is a highly specialised epoxy resin floor repair that includes oil tolerant resins in order to adhere to oil contaminated substrates.  An absolute must for many garages and engineering workshops.

5) We do indeed have many other hole fillers and mortars and our technical experts, most with years of practical experience, will be more than happy for a quick call to give you free and honest advice.

Etching the Concrete / Removing Loose Dust or Paint

It is imperative to remove any loose or friable material, including any loose paint from the surface prior to painting.

Chemical Cleaning – Polycote Etch IT

If it is only dust to be removed, the Polycote Etch IT is an ideal solution to help achieve this. However, you might need to consider that the floor will have to be given time to dry before the application of most paints and this inevitably means longer downtime and inconvenience. If speed and time is of the essence, then we would suggest you consider the use of mechanical preparation equipment.

Mechanical Preparation

The most popular machines would be a Vacuum Assisted Shotblaster, a Diamond Grinder and/or an STR machine.  Whichever machine you choose, we strongly suggest you make sure they are ‘Vacuum Assisted’ as the dust extraction unit can help to contain as much as 95% of the dust removed from the substrate.

In Summary

The cleaning of the surface is imperative to the successful adhesion of your chosen paint or floor coating system and will also ensure the paint lasts for the longest period of time.

Unfortunately, so many people try to ‘skip’ the preparation process and in turn only end up with a paint that begins to peel and flake in a very short space of time.

Let me just make these three points loud and clear:

1) If you paint over dust and/or loose material, you might as well paint the sand on the seashore and then wonder why it’s all coming up.

2) If you paint over a previous coating that is flaking or peeling and has clearly not adhered to the substrate, you might as well paint over a sheet of paper and then wonder why it lifted!!!

We are of course very aware that both of these statements are obvious but sadly, you would be amazed how many people just ‘hope’ the new paint will miraculously stick to the strong substrate ‘below’.

3) We would of course like to finish on a good note.

‘With a little bit of effort and the right tools, you can transform your garage into a clean, organized, and attractive space to be proud of and by preparing the substrate properly, you can achieve a new and improved look for your garage floor, get rid of that annoying dust, make your cleaning far easier and finally, greatly enhance the floors durability, longevity and safety’.

Related Articles

Choosing the right Garage Floor Paint

Benefits of Painting Your Garage Floor

How To Stop Garage Floor Paint From Peeling

Polycote UK would like to take the opportunity to thank you for taking an interest in these product and application articles and hope they have been some help to you.

We would of course be pleased to answer any specific questions should you wish to contact us directly on 01234 846400 or email: help@polycote.com

 

Your garage floor is an essential part of your home and keeping it in good condition is crucial. One way to do this is by painting it with the ‘right’ paint. There are several options available, each with its own set of advantages and disadvantages. In this article, we’ll take a closer look at the different types of garage floor paint and help you choose the right one for your needs.

Epoxy Paint – Flortex Professional Garage Floor Paint

Flortex Professional is a 100% solids pure epoxy floor paint is the most popular and successful choice for garage floors due to its toughness and durability. It is a two-part system that consists of a resin and a hardener. When mixed, they form an impervious easy to clean and highly resistant to chemicals, oil, and water.  Furthermore, the coating will provide a tough and durable surface that will easily withstand heavy use, traffic, and equipment.  Available in a range of colours and finishes, Flortex Professional Garage Floor Paint can even be mixed with coloured flakes to provide added texture and flare.

Important note:

Prior to the application of the top-coat (Flortex Professional) it is important to prime and seal the surface with the most suitable epoxy primer to ensure the best adhesion possible. Please see our separate sheet ‘Choosing the Best Floor Primer’

Polyurethane Floor Paint – PB Floor Paint

If you’re looking for an extra-durable concrete floor paint but you’re on a tight budget, Polycote PB Floor Paint is a great option. This high-solids polyurethane based floor paint creates a tough, abrasion-resistant coating. Being polyurethane rather than oil or water-based, it is not as brittle as and will not chip so easily.

PB Floor Paint is a great option if you plan on using your garage as a workspace and is both easy to apply and lesser in price that the epoxy versions.  However, it’s not as resistant as epoxy paint to chemicals and oil spills, so if you plan on working on cars or other machinery, you may need to consider a different option.

Acrylic Latex Paint – Flortex Clearseal

Another cost-effective option for painting your garage floor is Flortex Clearseal, which is a clear acrylic latex paint. This type of paint is easy to apply and dries quickly, making it an ideal choice to help seal the surface and hold back the dust.

In Conclusion

Ultimately, the type of garage floor paint you choose will depend on your needs, budget, and preferences. Consider factors such as durability, ease of application, and resistance to chemicals and oil spills when making your decision.

However, our final strong advice is ‘Don’t Go Cheap’. If the paint you choose does not stick to the floor due to underlying problems such as loose dusty surface, rising damp or oil contamination, it will obviously start to flake and peel – and the labour and equipment needed to remove the failed coating, before re-painting, will most likely cost more than the paint itself!

Remember:

1. A floor with flaking paint looks far worse than one not painted at all.
2. Loose and flaking paint MUST be removed before re-painting otherwise you will be totally wasting your time! To paint a previous coating that has not stuck to the floor, you might as well paint over a sheet of paper and then wonder why the paint didn’t stick to the floor!!!   Pretty obvious we know, but you would be amazed how many people just ‘hope’ the new paint will miraculously stick to the concrete.

Do it once and do it right!  With the right garage floor paint, you can keep your garage or workspace looking great for many years to come and as a proof to that statement, we have customers working daily on garage floors that were painted 10, 15 and 20 years ago!

Related Articles

Preparing Your Garage Floor for Painting

Benefits of Painting Your Garage Floor

How To Stop Garage Floor Paint From Peeling

Polycote UK would like to take the opportunity to thank you for taking an interest in these product and application articles and hope they have been some help to you.

We would of course be pleased to answer any specific questions should you wish to contact us directly on 01234 846400 or email: help@polycote.com

 

It is well known that there are hundreds of suppliers selling hundreds of different types of paint from hundreds of manufactures. So, for the business owner, finance director or maintenance manager, this becomes a lottery as to which manufacturer you should use and what type of paint you should buy.

There is hardly a person or company that has not experienced a failure of either a floor paint or screed and as a consequence, have wasted so much time, effort, and money.  A cheap paint may appear more enticing but when factoring in the inconvenience and cost caused by production downtime, it pays to make a wise and educated decision so as not to end in failure and frustration.

So, for your confidence and encouragement, this article is written by the owner of Polycote UK, a company known and respected for their professionalism and knowledge gained from over 30 years of hands-on practical experience, installing floor paints and screeds in almost every type of industry, nationwide.

So, to this end, we hope this step-by-step guide will be of great help to you in arriving at the best paint solution – for your own specific needs.

Factors to Consider When Selecting Floor Paint

Before any supplier can ‘arrive’ at the correct paint solution for your specific needs, they need to know the answers to all the following questions.  Only then, can they provide you with a long-term solution.

The list shown here will serve as a simple index as we will delve into each question individually.  Whilst there are obviously hundreds of different case scenarios, we will try to provide answers that will at least help provide an overview of all aspects and type of substrate. Some of the points may not be relevant to you in which you can ignore the question, hence why we have numbered this index to enable you to find a specific point relevant to your needs.

1. Why do you want to paint / repaint the floor?
2. What type of substrate do you have?
3. Is the floor new or old?
4. Is the substrate strong and sound, or is it weak and porous?
5. Is there a DPM (Damp Proof Membrane)?
6. Do you have any oil, grease or chemical contamination?
7. Has the floor been previously painted with a floor paint or sealer?
8. What amount and type of traffic will the floor be subjected to?
9. Will the floor need any specific chemical resistance?
10. Do you want to apply the floor yourself or do you require labour?
11. How much time can you spare to complete the work?
12. What temperature will the area be at the time of application?
13. Cost or Investment?

1. Why do you want to paint / repaint your floor?

To the average customer, these questions might sound a bit unnecessary BUT it is important and crucial we ask the questions.  If I as a supplier do not know exactly WHY you want to paint the floor, then it is impossible to intelligently meet your needs and expectations.

So, the most common reasons for wanting to paint the floor are:

a) Stop the dust.

b) Waterproof the floor.

c) For chemical resistance to prevent oil penetration or chemical attack.

d) For purely aesthetic reasons, such as a showroom.

e) For safety / slip-resistant reasons.

f) To protect the substrate from impact damage.

g) To help prevent wear and tear and prolong the life of the concrete.

h) To stop rising damp.

If it is a case of repainting the floor, all of the above questions are still relevant, but these further questions are even MORE crucial, because if we do not know why the existing coating has ‘failed’, then it is impossible to intelligently offer a solution!

If its simply a case of the fact that the original floor was a good quality floor, has all stuck solidly for the last 20 years and is simply a case of becoming tired and worn, then that is simple.  However, if it is a case that the floor is peeling, lifting, flaking and/or bubbling, then these are the most common points we would like you to consider / do:

1. Peel a piece of paint off the floor, turn it over a look at the back. What do you see?

a) It is covered in dust/concrete particles?

This shows that the paint has adhered 100% to the surface of the substrate, but unfortunately the substrate has failed /delaminated from the surface, which in turn is why the paint has ‘come away’ from the substrate.

This can be for two main reasons:

• The quality of the substrate is poor/weak and needs strengthening.
• The surface was not prepared sufficiently by removing the loose particles/laitance from the surface prior to the application of the paint.

b) The piece of paint has come off the floor and the back side is ‘as clean as a whistle’.

For there to be no evidence of the substrate stuck to the back of the sample simply and bluntly proves zero adhesion to the substrate and it is most important that you find out why!

• Was the floor sealed and therefore preventing any penetration and/or adhesion to the substrate?
  • Pour some water onto the bare concrete, from where you have just taken your sample. If the water, simply sits as a blob on the surface of the concrete this would strongly suggest a clear sealer has been used and is causing the ‘barrier’.
  • Concrete is naturally porous and therefore if the water penetrates the surface (seen by the concrete becoming darker) then this shows it has not necessarily been sealed. You may then have to consider…
• The presence of some other ‘external influence’ that is causing zero adhesion, such as waxes, oils, and silicone’s. There are obviously many and varied types, and you are best to find out what ‘they’ might be.

However, and in fact, whilst it is always best to KNOW what product is causing the paint not to stick, and the whole purpose of this article is promoting the need to be intelligent, when all is said and done and whatever the reason, you will need to ‘cut through’ this barrier.  So just by way of a suggestion, the use of a chemical acid treatment or better still to mechanically abrade the surface will help you remove the surface and expose the porosity of the concrete.  Just remember that whatever is on the surface, this may well have penetrated the substrate and you may need to remove more than just the very top surface! Very simply, if you don’t get ‘past’ this barrier and re-expose the pores, you will more than likely continue to get delamination and failure!

c) There is clearly dampness within the concrete.

This shows that the floor was either wet at the time of application and therefore the paint did not adhere.  This can be that the floor was cleaned by washing and then not left to dry sufficiently prior to the application of the paint.

Or…, there is an underlying issue with ring damp, caused simply by one of two reasons, zero DPM or a damaged/failed DPM.

If damp is the reason for failure, particularly rising damp, then it is imperative that the floor is sealed with one or two coats of a liquid DPM, such as Polycote DPM Primer.

d) There is the presence of oil.

Oil is both a serious and dreadful problem when trying to paint a floor.  The main reason for this is that there are very, very few products that will remain stuck to an oil contaminated floor.  The reason for this is actually very simple.  Firstly, the oil penetrates down into the concrete. You work hard and clean the floor thoroughly, returning it back to its former glory, and you are very pleased with the result.  You then paint the floor and wham, after what is only a fairly short space of time the floor begins to lift and peel.

The reason why we stated it as a ‘dreadful’ problem is that it is IMPOSSIBLE to get all the oil out from within the concrete, thus you have a never-ending problem!!!

However, all is not lost because there IS a way out – Polycote OT Primer!  This highly advanced twin pack epoxy has been professionally formulated to adhere to oil contaminated floors and has been proven in some of the worst and almost unbelievable situations.

2. What type of substrate do you have?

This question is really a ‘two-pronged’ question; firstly, the type of material whether it be concrete, wood, etc, and secondly, the strength or ‘state’ of the substrate, whether it is soft or hard, rusty or clean, whatever!

For instance:

Concrete:  Is it very porous or is it very hard?

Metal:        Is the surface rusty or clean?

Tiled:         Ceramic, quarry, terrazzo, or vinyl?

Important!  We would like to make this point absolutely clear…

… if the first coat doesn’t stick, no matter how much you pay for any subsequent coating or screed, it will fail.  The topcoat can only be any good if the first coat (this includes any existing paint) has truly adhered to the substrate.

Therefore, please remember that it is crucially important to ensure you apply a product specifically designed for or compatible with your substrate.

3. Is the floor new or old?

If the floor is old, then this surely raises all of the questions as listed.  However, one of the biggest causes of failures is when people think a ‘new’ floor is perfect to paint.  Unfortunately, 99 times out of 100, this is far from the truth!

New laid and untreated floors are extremely porous and attract every bit of contamination possible, especially when vehicles and trucks have been driven over them during construction.  Rubber from tyres as well as oil drips and spills. Plaster, paint and over spray from other trades. And the biggest problem of all – dust and surface laitance.  Remember the smoother the floor, the finer the particle and this is very simply why every factory experience terrible and on-going dust issues.

Even with brand new and well power floated floors, we would NEVER, as a professional contractor paint such floors without first preparing them professional mechanical equipment such as vacuum assisted diamond grinders or shotblasters.  In the right hands, these machines will not cause ‘damage’ but will do what is absolutely necessary to achieve a long lasting and successful installation.  We can PROVE the difference very easily by showing our warehouse.  This was used for its first 24 years as an HGV workshop and was impregnated with all sorts of ‘stuff’ and had worn and peeling paint everywhere.  In fact, it was painted every 3 months for 24 years.  We came in, shotblasted what was left off the floor, primed with OT Primer on the old, original concrete, shotblasted the new extension floor to remove the laitance and primed with WD Primer and top coated with Flortex Professional.  At the time of writing (21 years later), these floors have never been repainted and are still going strong!!

4. Is the substrate strong and sound, or is it weak and porous?

Even if the substrate is sound and strong, it is always advisable to ‘key’ the substrate using suitable mechanical equipment, if at all possible, to ensure a good adhesion.  However, if it is weak and porous, often in such circumstances, no matter how much you remove from the surface, whatever is left is still weak/poor.   Obviously, each matter needs to be considered on an individual basis, but the only real way to be able to achieve success on such a substrate is to ‘flood’ the floor with a suitable low viscosity pure epoxy.  The ‘pure’ epoxy is not water or solvent based and cures only by chemical reaction.  Therefore, it can be applied thickly, enough to be able to penetrate well into the substrate and fully cure ‘within’ the substrate, thus almost turning the existing concrete into ‘a form of’ an epoxy screed.  However, as I have made clear above, each situation needs to be carefully considered and all comments given here are in good faith and as advisory.  Whilst we do not wish to cast doubt upon the above comments, it must remain the customers responsibility and decision as to how they might wish to proceed.

We sincerely hope this is acceptable and understood.

5. Is there a DPM (Damp Proof Membrane)?

If your floor has rising damp, due to a damaged/poorly installed DPM or more commonly, no damp proof membrane, particularly on older buildings), rising damp is a major reason why floor paints and screeds fail.

Now just as a further point, you may not know whether there is a DPM or not and it is well worth trying to establish the fact BEFORE any such failure. The main reason that the rising water is only coming up fairly slowly and as it does so, it evaporates and therefore leaves no real evidence.  Of course, it might become apparent if a roll of carpet has been stored directly onto the concrete and when moved shows signs of mold, or maybe cardboard boxes, where the cardboard has become rippled and weak.

So, two of the most common ways to test the area(s) in question for the presence of

Damp are as follows:

• simply tape a sheet of plastic to the floor and leave for a few days. The plastic will cause the floor to sweat and will help draw any dampness within the concrete to the surface.
• lay down a rubber car mat and again, leave for a few days to see if any dampness is evident.

If indeed the floor does show signs of dampness, then you are strongly advised to use a primer such as Polycote DPM Primer, a twin pack epoxy resin primer formulated specifically to adhere to surfaces where rising water may be present.  However, please note that such primers are not suitable where water is ‘running’ into the area as the resin will not have time to cure before being affect by such water.

Finally, we would like to make it clear that these two methods are only advisory and by no means a foolproof method.  However, they will certainly give a very good indication.

6. Do you have any oil, grease, or chemical contamination?

All surface contamination such as a build-up of oil or grease should be removed before the application of any paint or screed. This can be accomplished with suitable machinery or with the aid of chemical degreasers such as Polycote Degrease IT.

However, with thinner chemicals such as oil, this penetrates down into the pores of the concrete and after you have thoroughly cleaned the surface, the oil within the substrate then rises up back up to the surface by capillary attraction and now your floor is oily again.  Unfortunately, there is nothing you can do about this as it will happen over and over again.

The problem when applying a paint even directly after the surface has been cleaned is because the paint is impervious and can therefore make the floor ‘sweat’ which draws up the oil under the paint and hey-presto, you have a failure!  And an expensive one!

If you have the evidence of oil, we strongly advise and oil tolerant primer such as Polycote OT Primer, that has been professionally formulated to be able to bind up to 15% oil into itself whist curing and thus adhere strongly to the substrate in question.

7. Has the floor been previously painted with a floor paint or sealer?

If the floor has been previously painted with a floor paint or sealer, please make absolutely sure that any paint left on the surface (prior to your new paint or screed) has fully adhered to the surface.

If you have any flaking or peeling paint, then it is absolutely vital you remove all the existing paint, down the hard substrate.  This is mostly achieved with the use of vacuum assisted machinery such as diamond grinders and/or shot blasters.

This further note may sound a little rudimentary but please remember that if you apply a coating or screed over an existing paint that has not adhered well to the surface, you might as well paint over a sheet of A4 paper and wonder why your new paint is lifting!

You simply MUST remove all loose, flaking, peeling material if you want a success long lasting job.

8. What amount and type of traffic will the floor be subjected to?

Obviously, the type and amount of traffic that the floor will be subjected to will determine the type of coating used.

Single pack floor paints can be very good but for areas of heavy wear and tear, twin pack epoxies will last far longer. Furthermore, due to the fact that they can cure to an impervious finish, they are also far more waterproof and/or chemical resistant and also, far easier to keep clean. Floor coatings such as Flortex Professional are strongly advised for areas such as factories and warehouses with the constant trafficking of heavy forklifts and pallet trucks.

For areas that need to withstand vehicular traffic such as cars and trucks, particularly in garages and manufacturing facilities, standard paint will not withstand hot car tyres, etc and therefore twin pack epoxy floor paint such as Flortex Professional remains the number one choice for long term success.

9. Will the floor need any specific chemical resistance?

For the most part, a good quality paint, certainly a twin pack epoxy or polyurethane paint has a very reasonable chemical resistance that is suitable to withstand most ‘normal’ chemicals.  However, it is always advisable to make a list of the chemicals used in the area and the percentages of concentration such as 50% sulphuric or 10% acetic or 30% caustic, for instance.  Furthermore, do you have a particular cocktail of chemicals as such mixes can completely change the characteristics and/or volatility as this also need to be made very clear to any manufacturer.

Another point to consider is the amount allowed to come into contact with the coating. Submersion is a whole different matter from occasional splashing or spillages as is the amount of time the coating is left in contact with the paint. How long do you expect to leave it before cleaning it up as this can also have a completely differing number of effects on paint.

It is strongly advised that all these points should be noted and discussed with any supplier or manufacturer before any purchase is made and/or any application is carried out.

10. Do you want to apply the floor yourself or do you require labour?

If you wish to carry out the work yourselves, it is highly advisable that you speak to companies such as Polycote UK, who not only specialise in the supply of floor paints and coatings, but who also have a full application team to carry out the preparation and application of the products.

With full support from a team of professional applicators happy to help throughout the application, from your initial inquiry as to the right product, the best type of preparation needed along with the provision of the machinery itself, the correct methods of application and right through to the point of completion, you will be assured of a company that is as interested and committed to success, as you are!

Obviously, if you are looking for the labour element as well, it is important that you find a company with a proven track record.  The fact that companies such as Polycote UK who have been in the trade for over 30 years, is far more important than so called guarantees and warranties that in most cases are not worth the paper they are written on! The sheer passage of time is a true testament to the professionalism, longevity and reliability of both products and service alike.

11. How much time can you spare to complete the work?

This is a very important question. Don’t forget that you will need to clear the area prior to the arrival of the preparation team.  The methods of preparation, such as diamond grinding and/or shot blasting can then expose poor areas of concrete that need repairing prior to the application of the floor paint. Then there is the floor painting itself which in most cases would need two coats and this being finally ‘topped’ off with the curing time of the final coat before subjecting it to traffic.

Whilst this might all sound daunting, you can rest assured that there are products available that can cure very fast and be subjected to heavy traffic is as little 20 minutes.  There are coatings available that can be applied in temperatures as low as minus 40°C and still be ready for traffic in as little as 1.5 hours.

Obviously, standard products are sufficient for most applications.  However, Polycote UK can tailor both their products and services around your own specific timing parameters should such a need arise.

12. What temperature will the area be at the time of application?

In most situations, paints are applied in ambient temperatures of between 10-25°C.

However, there are times when the application area is influenced adversely by weather or operations.  Some areas being very cold, such as cold storage facilities down to minus 40°C, food factories, often running between 2-8°C, through to bakeries with ovens running in excess of 80°C and smelting plants with operating temperatures of 200°C. Polycote can manufacture products that will can both cure and withstand the extremes in all of these areas and will be more than happy to discuss your specific requirements with you.

Cold conditions:

It is worth noting that the colder the temperature, the longer the curing time of the coating will be, and it is in these situations when extra fast hardening resins can be used to help speed up the curing process/times.  However, please also note that the use of extra fast hardeners will mean a shorter pot life once mixed so this does need careful consideration.

Hot conditions:

There are times when products need to be applied in hot conditions and it is therefore very important to acquaint yourself with the manufacturers data sheet, which will state the pot life of the materials once mixed.

In hot temperatures, it is often a great help if the manufacture can be asked to produce smaller unit sizes, which helps enable the operatives to be able to apply before the curing process gets to the point where application is no longer possible.

13. Cost or Investment?

Our advice for is: try not to look at painting the floor as a ‘cost’ but more as an ‘investment’!

To coat the floors not only strengthens the concrete but seals and protects from contamination.  A sealed floor rather than a porous surface makes cleaning routines far quicker and easier, thereby saving time, effort, and money.  A painted floor makes the entire environment a far brighter and happier place to work, which has been proven to raise the morale of the employees as well as the productivity!

Furthermore, it has also been proven that a well presented and well-marked out factory/warehouse has massive safety benefits, thereby helping to reduce accidents and consequential disruption to the business.

Finally, by investing in a high-quality paint, lasts far longer and therefore reduces the need for frequent recoating.

When considering all of the above points, a good quality paint is truly an investment whereas a cheap, poor job always ends in a far greater cost!

Here are a few ‘sayings that we hope may encourage and help you to make a right decision:

“It is always cheaper to do the job right, the first time.”  Philip B. Crosby

“It’s hard enough to do it the first time, so do it once and do it right!”  S. Britchford

“Cost is more important than quality, but quality is the best way to reduce cost.”  Genichi Taguchi

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So why wait? Transform your floors and working environments today and reap the rewards that extend far beyond simple aesthetics. If you are genuinely looking for a long term solution, then ring Polycote now on 01234 846400 and speak to one or our advisors who, very simply, can tell you exactly WHAT you should use and WHY!

Improved Appearance

A dull, stained garage floor can detract from the overall look of your garage, making it a less attractive space to work in and less attractive to your customers. Conversely, to paint the garage floor will transform its appearance, making the space more visually appealing and a far more pleasant customer experience.

With a wide variety of colours and textures to choose from, you can create a custom look that matches your preferences and style.

If you want a sleek and modern look, you can choose a high-gloss finish in a bold colour such as red or blue. If you prefer a more rustic or industrial look, you can choose a textured finish that resembles stone or concrete, even a clear coating. The possibilities are endless, and the result is a garage floor that is not only functional but also looks great.

Corporate Image

In today’s age, it is not only difficult to attract customers to your garage but with increasing competition, we realise that customer retention is equally important.

Corporate image was normally reserved for paperwork, the sign above your door and employees dress code. However, commercial garage floors are now becoming a major part of a professional corporate image.

For the larger customers with several branches, who have left each branch to sort out its own floors with varying degrees of success, along with whatever type of paint and colour they might choose, companies now realise this is far below the standard expected if they are to gain customers and loyalty.

Even the same line marking paint!  Why should you have one branch have yellow lines and another have white?  Why should one branch have 4” wide lines and another with 2” wide?

A full colour scheme can be discussed to ensure all branches are fully aligned with each other and bring in a complete transformation to propel your company into the 21^st century!  We will supply the same product and the same company colours to all branches and ensure that each branch can be quickly and easily recognised, not only by customer but suppliers too, no matter whether it is in Plymouth, London, or Edinburgh.

We also highlight the benefits of what we term as ‘Corporate Safety’ and these are mentioned separately.  Please see the subsection entitled ‘Corporate Safety’ below.

Enhanced Safety

By painting your garage floor, you can help enhance the safety of your garage. The paint can add traction, reducing the likelihood of slips, trips, and falls. This is especially important if you have elderly relatives or young children who visit your home frequently.

In addition to adding traction, a painted garage floor can also help with visibility. A brightly coloured floor, such as grey or white, can make it easier to see tools, equipment, and other items on the floor, reducing the risk of accidents. This is especially important if you use your garage as a workspace or if you store hazardous materials in the space.

‘Corporate’ Safety

Safety is an extremely important part within the Corporate Imaging of the company and to this end, the colour coding of specific areas is an important consideration and covers all personnel, no matter whether it is customers, employees and/or suppliers.

Customers

This can include the clear demarcation of waiting areas, customer inspection areas and fire escape routes.

Suppliers

Many garages now colour code both the goods in and goods out areas which they have proven to massively help suppliers and couriers to identify quickly and easily where goods should either be left or collected from.  Garages, particularly large venues can also save a huge amount of time and cost as both suppliers and employees know exactly where products can be found.

Employees

The colour coding of sites has huge safety advantages. Walkways and hazardous areas are easily identifiable. Even fire extinguisher and fire hose positions can be easily defined for quicker identification in an emergency.

Furthermore, this all has a massive advantage as and when employees visit different sites within the company.  Colour coding is self-explanatory, and employees are able to instantly identify any hazardous areas and/or where to look for emergency equipment which has further proved a reduction in the amount of both accidents and injuries.

Increased Durability

Painting your garage floor helps protect it from damage due to wear and tear, such as cracks, chips, and stains. The paint forms a protective barrier, which helps prevent damage from moisture, chemicals, and oil. This added durability can prolong the life span of your garage floor, saving you the cost of repair or replacement in the long term.

In addition to protecting your garage floor from damage, painting it can also make it more resistant to extreme temperatures. This is especially important if you live in an area with harsh winters or hot summers. The paint can even help regulate the temperature of your garage, making it a more comfortable space to work in year-round.

Easier Maintenance

A painted garage floor is easier to keep clean than one with bare concrete. The smooth, coated surface makes it simple to sweep or mop up spills, making the garage floor more functional for everyday use. This is especially important if you use your garage as a workspace or if you have children or pets who spend time in the space.

With a painted garage floor, you don’t have to worry about dirt and grime getting ground into the concrete, which can be difficult to remove. Instead, you can simply wipe the surface clean with a damp cloth or mop, keeping your garage floor looking clean and tidy with minimal effort.

A smart Investment

Painting your garage floor is a simple and cost-effective way to improve the appearance, durability, maintenance, and safety of your garage. With so many colours and textures to choose from, you can create a custom look that matches your preferences and style. Whether you use your garage as a heavy duty commercial workspace or simply as a place to park your car, a painted garage floor is a smart investment that can pay off in the long term.

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Polycote UK would like to take the opportunity to thank you for taking an interest in these product and application articles and hope they have been some help to you.

We would of course be pleased to answer any specific questions should you wish to contact us directly on 01234 846400 or email: help@polycote.com

 

 

In this comprehensive guide to different types of concrete floor sealers we will explain how concrete floor sealers play a crucial role in protecting and enhancing the durability of concrete floors. Whether you have a residential or commercial space, understanding the importance of these sealers is essential.

Each sealer has its own unique properties and applications.  Whether it be to reduce dust, strengthen the surface, resistance to liquids or increase protection from the damaging effects of ultra-violet light.

There are many types of sealers available in the market. It is important to choose the right floor sealer for your specific needs. Here are some pointers at the more commonly used sealers, that we hope will be of interest and help to you:

Acrylic Sealers

One popular choice among homeowners and contractors is acrylic sealers such as Flortex Clearseal from Polycote. These sealers are known for their affordability and ease of application and provide a durable protective layer.

The versatility of acrylic sealers is evident in the fact that they are available in both solvent-based and water-based formulations. They offer different levels of glossiness. This means you can choose a finish that suits your aesthetic preferences. Acrylic sealers are suitable for both interior and exterior concrete surfaces that experience light to moderate foot traffic.

One of the key advantages of acrylic sealers is their ability to enhance the colour of the surface. This is particularly beneficial if you have decorative concrete you would like to protect and showcase. Additionally, acrylic sealers are resistant to UV rays, making them a great choice for outdoor surfaces exposed to sunlight.

Epoxy Sealers

If you’re looking for a sealer that offers superior durability and chemical resistance, epoxy sealers such as Flortex Fastset are worth considering. These sealers form a tough and glossy finish that can withstand heavy traffic and harsh chemicals. That’s why they are often used in industrial settings, garages, and warehouses where the concrete is subjected to high levels of wear and tear.

Epoxy sealers provide a strong barrier that protects the concrete from stains, oil, and other contaminants. This makes them a popular choice for areas where spills are likely to occur as they can have far greater chemical and wear resistance. In addition to their protective properties, epoxy sealers can also enhance the appearance of the concrete by adding a glossy finish. This can be particularly appealing in commercial spaces where aesthetics play a crucial role.

Penetrating Sealers

Whether it be the sealing of internal floors from dust and liquid spillages. Outdoor surfaces that need protection against water damage and de-icing salts, penetrating sealers are an excellent choice. These sealers work by penetrating into the concrete, forming a protective barrier beneath the surface.

Another major benefit of applying sealers designed to penetrate well into the surface such as Flortex PU, they massively help to increase the strength and wearability of the substrate as well as sealing it at the same time.

Should the surface be loose or weak, twin pack ultra-low viscosity epoxy primers/sealers such as Polycote EP Primer are the ultimate choice. They are professionally formulated to penetrate well into the surface. Due to the twin pack chemical curing of the resin, these products will fully cure within the substrate and thus can turn the existing ‘plain’ concrete into ’a form of’ epoxy screed!

Finally, one of the main advantages of penetrating sealers is that they do not alter the appearance of the surface and help maintain the natural look of the concrete.

Polyurethane Sealers

If you’re looking for a sealer that combines durability with a high-gloss finish, single pack polyurethane sealers such as Flortex PU Clear are a great option. These sealers offer excellent resistance to abrasion, chemicals, and UV rays, making them suitable for a variety of applications.

Polyurethane sealers are commonly used in commercial spaces, showrooms, and retail environments where aesthetics and durability are equally important. The high-gloss finish provided by polyurethane sealers can give your concrete floors a polished and professional look.

It’s important to note that polyurethane sealers are typically more expensive than acylic sealer. However, their long-lasting performance and ability to withstand heavy foot traffic make them a worthwhile investment.

Should wear and tear and ultimately longevity be a major concern to you, then it would be a good idea to explore twin pack polyurethanes such a Flortex PU Twin Pack as these products offer the highest levels of strength and resistance to damage.

In Conclusion

In conclusion, we hope this comprehensive guide to different types of concrete floor sealers provide you all the information you need when choosing the right concrete floor sealer. We have explained it is essential for protecting and enhancing your concrete surfaces. Whether you opt for acrylic, epoxy, penetrating, or polyurethane sealers, each type has its own unique benefits and applications. Consider factors such as foot traffic, exposure to chemicals, and desired aesthetic appearance when making your decision. By selecting the appropriate sealer, you can ensure that your concrete floors remain beautiful and protected for years to come.

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Polycote UK would like to take the opportunity to thank you for taking an interest in these product and application articles and hope they have been some help to you.

We would of course be pleased to answer any specific questions should you wish to contact us directly on 01234 846400 or email: help@polycote.com