Flowfresh - : Antimicrobial Flooring
Flowfresh - : Antimicrobial Flooring
Flowfresh - : Antimicrobial Flooring
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Beverage Industry
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TABLE OF CONTENTS
INTRODUCTION 4 3.4 EXISTING FLOWFRESH URETHANE
1. About Flowfresh 5 CEMENT SURFACES 13
1.1 FLOWFRESH FLOORING GRADES 5 3.5 EXISTING MASONRY SURFACES 13
1.2 SITE Storage 6
1.2.1 Special Considerations 6 4. PRE-APPLICATION PLANNING 14
1.2.2 Uniform Temperature 6 4.1 GOOD OPERATIONG PRACTICES 14
1.2.3 Ideal Storage Temperatures 6 4.2 MIXING STATION 14
1.3 SHELF LIFE 6 4.3 INSTALLATION PLANNING 14
1.4 COLD TEMPERATURE APPLICATION 6 4.4 MARGIN TREATMENTS 15
1.5 HOT TEMPERATURE APPLICATION 7 4.5 JOINT TREATMENT 15
1.6 SAFETY 7 4.6 CHAMFERING 15
1.7 ULTRAVIOLET AND 4.7 SPECIAL CONSIDERATIONS 16
EXTERIOR APPLICATIONS 7
4.8 PRIMING AND SCRATCH COATING 16
2. PREPERATION OF SUBSTRATE 8
5. MIXING OF FLOWFRESH MATERIAL 17
2.1 CONCRETE SUBSTRATES 8
5.1 MIXING EQUIPMENT 17
2.2 EXPANSION & CONTRACTION JOINTS 8
5.2 MIXING PROCEDURE 18
2.2.1 Contraction (Control) Joints 8
5.3 MIXING PROBLEMS 19
2.3 MEMBRANE (use of Flowfresh as) 8
5.3.1 Over-mixing 19
2.4 SUBSTRATES 8
2.5 SURFACE PREPERATION 9
6. APPLICATION TOOLS 20
2.5.1 Primary Requirements 9
6.1 Minimum Recommended
2.5.2 Acceptable Methods 9
Application Equipment 20
2.5.3 Surface Profile 10
6.1.1 Flowfresh HF & RT 20
2.6 MOISTURE 10
6.1.2 Flowfresh SR/SRQ 20
2.7 HOLES AND CRACKS 10 6.1.3 Flowfresh MF 20
2.7.1 Holes, Voids and Depressions 10 6.1.4 Flowfresh SLB 20
2.7.2 Unapproved Materials for 6.1.5 Flowfresh CM 20
Patching and Filling 11
2.8 FLOOR FLATNESS FACTORS 11 7. APPENDIX 21
2.9 SLOPE & PITCH 11 7.1 CLEANING AND MAINTENANCE 21
7.1.1 Cleaning & Maintenance 21
3. ALTERNATE SUBSTRATES 12 7.1.2 Post-installation 21
3.1 MILD CARBON STEEL (i.e. diamond plate) 12 7.1.3 Service Cleaning 21
3.2 EXTERIOR GRADE PLYWOOD 12 7.1.4 CIP 22
3.3 APPLICATION TO EXISTING 7.2 MAINTENANCE & REPAIR 22
POLYMER AND MASONRY SURFACES 12 7.3 APPROVED EQUIPMENT SOURCES 23
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INTRODUCTION
This manual is intended as a guide for flooring contractors and engineers installing Flowfresh urethane
cement flooring products in industrial applications.
This guide is offered as a resource to contractors and engineers. Proper specification and successful
completion of Flowfresh installations is the sole responsibility of the engineer and contracting installer.
This manual contains information which is correct to the extent of our knowledge.
Flowfresh materials require specific skills, tools and equipment. Flowfresh materials are intended for
installation by experienced contractors with requisite skills and experience.
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1. About Flowfresh
1.1 FLOWFRESH FLOORING GRADES
Type Description Components Unit Weights Standard Thickness and
and Surface Packaging Coverage
Texture (Theoretical per
complete Unit)
RT Heavy Duty, Slip Resin: White liquid Resin: 5 lb net Resin: 3 quart bottle 28 Ft2 @ 3/16”
Resistant Pigment pack: Blended Pigment Pack: 1 lb net Pigment Pack: Paper bag 21 Ft2 @ 1/4“
powder Hardener: 5 lb net Hardener: 3 quart bottle 14 Ft2 @ 3/8“
Hardener: Brown liquid Filler: 44 lb bag Filler: Moisture resistant
Filler: Blended powder paper bag
HF Heavy Duty, Slip Resin: White liquid Resin: 5 lb net Resin: 3 quart bottle 24 Ft2 @ 1/4 “
Resistant Pigment pack: Blended Pigment Pack: 1 lb net Pigment Pack: Paper bag 17 Ft2 @ 3/8 “
powder Hardener: 5 lb net Hardener: 3 quart bottle
Hardener: Brown liquid Filler: 55 lb bag Filler: Moisture resistant
Filler: Blended powder paper bag
IF Heavy Duty, Slip Base: White liquid Base: 5 lb net Resin: 3 quart bottle 14 Ft2 @ 3/8 “
Resistant Pigment pack: Blended Pigment Pack: 1 lb net Pigment Pack: Paper bag
powder Hardener: 5 lb net Hardener: 3 quart bottle
Hardener: Brown liquid Filler: 51 lb bag Filler: Moisture resistant
Filler: Blended powder paper bag
SR Medium Duty, Slip Resin: White liquid Resin: 5 lb net Resin: 3 quart bottle 24 Ft2 @ 3/16”
Resistant Pigment pack: Blended Pigment Pack: 1 lb net Pigment Pack: Paper bag (1/4” system)
powder Hardener: 5 lb net Hardener: 3 quart bottle
Hardener: Brown liquid Filler: 36 lb bag Filler: Moisture resistant
Filler: Blended powder paper bag
MF Medium Duty, Resin: White liquid Resin: 5 lb net Resin: 3 quart bottle 22 Ft2 @ 3/16”
Smooth Pigment pack: Blended Pigment Pack: 1 lb net Pigment Pack: Paper bag 17 Ft2 @ 1/4”
powder Hardener: 5 lb net Hardener: 3 quart bottle
Hardener: Brown liquid Filler: 29 lb bag Filler: Moisture resistant
Filler: Blended powder paper bag
SLB Light/Medium Base: White liquid Base: 10 lb net Resin: 1 gallon bottle 24 Ft2 @ 100mils
Duty, Slip Pigment pack: Blended Pigment Pack: 1 lb net Pigment Pack: Paper bag (3/16” system)
Resistant powder Hardener: 10 lb net Hardener: 1 gallon bottle
Hardener: Brown liquid Filler: 40 lb bag Filler: Moisture resistant
Filler: Blended powder paper bag
FC Primer, (or) Lock Resin: White liquid Resin: 5 lb net Resin: 3 quart bottle 120 Ft2 per unit
Coat Pigment pack: Blended Pigment Pack: 1 lb net Pigment Pack: Paper bag (on BCM quartz)
powder Hardener: 5 lb net Hardener: 3 quart bottle
Hardener: Brown liquid Filler: 6 lb net Filler: 1 gallon plastic pail
Filler: Blended powder
CM Cove Mortar Resin: White liquid Resin: 2.5 lb net Resin: 1/2 gallon bottle 11 Ft2 @ 3/16”
Pigment pack: Blended Pigment Pack: 1 lb net Pigment Pack: Paper bag 33 ln Feet for 4 inch
powder Hardener: 2.5 lb net Hardener: 1/2 Quart bottle x 3/16” cove
Hardener: Brown liquid Filler: 26 lb bag Filler: Moisture resistant
Filler: Blended powder paper bag
Note: Flowfresh SR is used as the bodycoat for both Flowfresh SR and SRQ systems. These systems
required a lock-coat, a variety of which are available dependant on the end use of the floor.
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1.2 SITE STORAGE
Flowfresh flooring materials and related materials must be properly stored to assure proper
performance and to prevent damage to the components prior to installation. All materials must be
stored under cover, raised clear of the floor and in a temperate, dry environment.
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1. Workability: All grades of Flowfresh will be more viscous and more difficult to apply.
2. Productivity: Low temperatures will significantly reduce installation rates and increase the
amount of time required to produce satisfactory finishes.
3. Curing time: The amount of time required for Flowfresh materials to properly cure and achieve
satisfactory physical properties will be increased at lower temperatures.
1.6 SAFETY
Observe all safety requirements as outlined in the MSDS, application data sheets and commonly
accepted industrial safety practices. Blended Flowfresh materials in mass will generate significant
amounts of heat and carbon dioxide gas. Do not seal containers with reacted Flowfresh material,
contained gasses will cause the container to explode.
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2. PREPARATION OF SUBSTRATE
No single element of Flowfresh installation will affect the service life of the floor more than substrate preparation.
Inadequate surface preparation will cause disbondment, pop-outs, cracks and other surface defects.
2.4 SUBSTRATES
Acceptable Substrates for Flowfresh Flooring Materials
The primary considerations for acceptable substrates are:
1. Soundness
2. Acceptable strength
3. Surface profile
Acceptable substrates are:
1. Portland cement based concrete
2. Polymer modified concrete
3. High-strength repair concrete/patching/leveling materials
Unacceptable substrates are:
1. Gypsum based floor leveling compounds
2. Sand-cement “mud” beds
3. Ceramic glazed tile (see exception for quarry below)
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2.5 SURFACE PREPERATIONS
All substrate surfaces, regardless of their composition, shall be properly prepared prior to application of
the Flowfresh materials.
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Surface preparation may be evaluated by the International Concrete Repair Institute
(ICRI Guideline 03732) which has established a standard grading system for concrete
surface preparation.
2.6 MOISTURE
Flowfresh products must be applied to visibly dry concrete. Flowcrete defines “visibly dry” as:
1. No reflective film of water
2. No darkening or discoloration
3. Passes ‘Paper test’: A piece of normal white composition paper is pressed into the surface of the
concrete with the heel of the hand. A 5 second press into the concrete surface shall demonstrate
no moisture absorbed onto the paper when the paper is observed under adequate lighting.
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2.7.2 Unapproved Materials for Patching and Filling
Unapproved materials for patching, filling of concrete prior to installation of Flowfresh materials:
1. Epoxy binders, regardless of formulations, shall never be used for patching or repair.
2. Gypsum based (lightweight) floor leveling compounds or screeds.
3. Poly- or vinyl ester thermosetting resins.
4. Latex based patching materials.
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3. ALTERNATE SUBSTRATES
Flowfresh materials are purpose-designed for application to sound structural concrete surfaces.
Under certain specific conditions Flowfresh may be successfully applied to alternate substrate
materials. These include:
1. Existing urethane cement
2. Existing epoxy flooring
3. Existing quarry tile and acid brick
4. Exterior grade plywood
5. Mild carbon steel
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2. Existing substrate should be subjected to acoustic testing (sounding) to determine general
condition and to locate disbonded areas.
3. Random adhesion testing should be performed by appropriate method.
a. Polymer surfaces should be tested by Elcometer pull-off tester per ASTM D451. All testing
results should indicate adhesion values in excess of 200 psi with concrete failure before
bond failure.
b. Masonry surface units (quarry tile, acid brick) should be tested by random removal of a
representative number of units. All units shall be soundly adhered, direct bond by epoxy to
sound concrete only. A soundly adhered tile or brick should have to be destroyed to
completely remove it.
c. Masonry units installed on sand-cement (low-strength) setting beds shall NOT be overlaid
with Flowfresh materials.
d. Grout lines in masonry units should be thoroughly inspected prior to overlay. Loose, cracked
and degraded grout shall be removed and replaced with polymer fill prior to preparation
and overlay.
4. Any existing substrate must be evaluated for the presence of contaminates. Oil, grease and
biological matter must be removed prior to preparation. This is of particular concern in grout
lines or masonry surfaces.
Disbonded, damaged or degraded areas must be removed and replaced with either high-strength
masonry repair material (Isocrete 4000) or Flowfresh MF.
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4. PRE-APPLICATION PLANNING
4.1 GOOD OPERATIING PRACTICES
The success of any Flowfresh installation begins with proper material handling and mixing. Prior to
beginning any Flowfresh installation, the contractor should:
1. Carefully plan the flow of material from the staging/laydown area to the mixing area.
2. Ensure that the temperature conditions of the material can be maintained during the entire
mixing and application process.
3. In the event that the material can not be staged directly by the mixing station, insure that the
material can be moved quickly and efficiently from the storage area to the mixing area. Ensure
that enough material can be staged adjacent to the mixing station to allow for uninterrupted
flow of material to the application area.
4. Ensure that intermediate areas between the mixing station and application area are
protected as required.
5. Ensure that power supplies are secure and will remain uninterrupted during the mixing and
application process. Provide for backup power supply if necessary. Also consider lighting
during application.
6. Isolate the mixing and application areas to prevent unauthorized persons from entering.
Post any applicable safety warning signs, notify appropriate personnel of activities.
.3 INSTALLATION PLANNING
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Prior to starting, carefully lay out the installation of product to the floor. The layout of the floor and the
resulting ‘cold’ joints should be agreed to with the engineer or Owner prior to starting.
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Establish ‘bays’ of installation, either following existing column lines, expansion joints or other structural
boundary. Take into consideration the width of the bay to avoid laying out too much material and
making sure that a ‘wet edge’ can be maintained at all times. Attempting to lay out too much material
along a line and failing to maintain a wet edge will result in laying new material into material that has
already begun to set. This will result in an unacceptable surface defect.
As a general rule, each ‘bay’ should not exceed 25 feet in width. In hot weather conditions this may
be reduced to accommodate a shorter cure time. Take into consideration as well the amount of labor
available to accomplish the installation and adjust accordingly. The total area of each bay should be no
greater than that which can be installed in the allowable time without stopping.
If installation ‘bays’ can not be cleanly terminated at a joint, use wood or steel strips the thickness of the
topping to establish a stopping point. Protect wood strips with duct tape, metal strips with tape or a coat
of wax. Remove the strips after the material has begun to set. Do not allow the strips to remain in place
until the material has fully set.
4.6 CHAMFERING
Identify and treat all areas that require chamfering or relieving to allow full thickness of material at
termination points. These are:
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1. Drains and trenches
2. Terminations to same level adjacent floor
3. Doorways, transoms, overhead doors
Treat these terminations in accordance with the construction details contained elsewhere in this document.
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5. MIXING OF FLOWFRESH MATERIAL
No single element of a Flowfresh installation will affect the application of the product more than proper
mixing. Improper mixing will result in:
1. Uneven or inadequate cure
2. Poor adhesion
3. Uneven coloration and surface texture
4. Premature failure in service
Flowfresh materials are packaged as unitized “kits” containing the proper amounts of each component.
Do not substitute any components. The Flowfresh Part C filler powder contains several essential active
components and must never be substituted.
THERE ARE NO APPROVED THINNERS FOR USE WITH FLOWFRESH MATERIALS. NEVER THIN ANY
FLOWFRESH MATERIAL. USE OF ANY THINNER WILL VOID WARRANTY.
Each type of Flowfresh material (except CM) uses the same Part A (resin) and Part B (hardener)
components. Each Flowfresh product uses a different type and amount of filler powder. Do not intermix
filler powder components from different products.
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5.2 MIXING PROCEDURE
Do not initiate mixing procedure until all personnel are prepared to immediately apply it to the
floor. Flowfresh® products are faster reacting and curing than many epoxy materials.
1. Stage materials convenient to mixing station. It is recommended that all the Base A and
Hardener B components be removed from their boxes, neatly arranged and the lids pre-
opened. This will expedite the movement of material.
2. Completely drain the Base A resin into the mixing bucket.
3. Turn on the mixer and install the side scraping mixer paddle.
4. Pour the Pigment pack into the mixing bucket and mix for 20 seconds.
5. Completely drain the Hardener B hardener into the mixing bucket with the mixer turning.
6. Allow the A, B & Pigment to pre-mix for ½ minute.
7. With the mixer continuously turning, add the entire contents of the Filler C filler. Mix for a
minimum of 60 seconds per bag. Push the side paddle mixing arm across the mix to insure
that all filler powder is consolidated in the material.
8. Remove the mixer paddle and transport the material to the application area.
Transporting the mixed material to the application area may be accomplished in the mixer container, or
in a plastic tray wheelbarrow. Steel wheelbarrows may be used; however, they will be more difficult to
clean. The mixed material should never be transferred from one container to another more than once.
After removing the mix, the sides of the mixer and the mixer paddle should be quickly scraped of
remaining material. If the mixer is to be immediately refilled, intermediate cleaning is not required
beyond a quick scraping of the mixer blade. If the mixer is to remain idle for more than 5 minutes,
it is recommended that it be scraped of remaining material and cleaned with solvent (see approved
solvents). Material remaining after 5 minutes which is reintegrated into the next mix may cause
premature hardening of the material and surface defects.
To ensure uniformity of shade and texture:
1. Use material from the same batch number and shipment.
2. Keep mixing times consistent.
3. Do not break down kits below normal kit size.
4. Mix quickly, rotate two buckets in mixer.
5. Do not allow the Flowfresh mixture to remain in a bucket, wheelbarrow, or be allowed to rest
on the floor in a pile. Any mixed material that has been allowed to rest in a container or on the
floor for more than 3 minutes shall be removed and disposed of.
Always mix the material quickly, move to the application area and spread out quickly and trowel or
finish quickly. Any delay has the potential to cause defects and deficiencies in the final product. These
deficiencies may include trowel marks, blistering or bubbling and uneven texture.
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5.3 MIXING PROBLEMS
5.3.1 Over-mixing
Be aware that Flowfresh materials will begin to generate heat (exotherm) during mixing. Over-
mixing beyond the time absolutely necessary to mix the Base A, Hardener B and Filler C will result
in shorter working times on the actual floor application.
In warmer weather, mixing time may be reduced to accommodate the lower (thinner) viscosity of
the mixed material and the shorter allowable mixing time.
In colder weather, longer mixing times may be required due to the higher (thicker) viscosity.
At temperatures below 60°F (15oC) mixing time may be increased approximately 50%. At
temperatures below 55°F (12oC) mixing time may be approximated doubled.
In all cases, mixing must be thorough enough to consolidate all of the powder into the
Flowfresh mix.
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6. APPLICATION TOOLS
Successful application of Flowfresh materials requires the use of ordinary mason’s tools as well as
specialized equipment for applying the materials at uniform thicknesses and imparting finish.
6.1.3 FLOWFRESH MF
1. Screed ‘pin’ or ‘cam’ rake with thickness adjustment
2. Porcupine or spike rollers
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7. APPENDIX
7.1 CLEANING AND MAINTENANCE
7.1.1 Cleaning and Maintenance
Flowfresh floors are extraordinarily durable and long lasting surfaces. They are impervious to
water, process liquids and solids. The integral Polygiene antimicrobial feature insures reliable
protection against bacterial and microbial growth. Flowfresh products have the added benefit of
being resistant to water at sanitizing temperatures which permits cleaning the floor surface to the
highest possible degree.
7.1.2 Post-installation
Cleaning and protection of the flooring material begins shortly after installation. If the Flowfresh
materials are installed during the initial construction phase, special considerations must be taken
to protect the floor prior to being put into service.
Heavy rubber tired equipment such as high-lifts, bobcats and forklifts may cause damage from
turning tires and imbedded dirt and soil.
Point loads from heavy static equipment placed on floor should be avoided for at least 48 hours
after application, longer at lower temperatures.
Following trades must protect the floor from spillage of paints, solvents, cutting fluids and welding
spatter. Brick mortar, wet concrete, tile grouts and other materials containing Portland cement
must not be allowed to come into contact with Flowfresh materials after installation as they may
stain or bleach the surface. Caustic materials such as paint strippers, drain cleaners and metal
de-scaler will also bleach and stain the surface.
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7.1.4 CIP
Some Clean-In-Place (CIP) chemicals, in full-strength form may cause damage to Flowfresh
surfaces. Care should be taken in areas where CIP chemicals are stored to prevent the routine
exposure of the Flowfresh flooring to full concentrations of:
1. Sodium hydroxide >50%
2. Nitric Acid
3. Phosphoric Acid
4. “Red” acid (nitric/phosphoric mix)
5. Peroxyacetic Acid
In areas where these chemicals are stored on Flowfresh flooring, take precautions such as drip
pans and routine wash down to reduce the concentration and accumulation of these and other
cleaning chemicals at very high concentrations.
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7.3 APPROVED EQUIPMENT SOURCES
The following list contains equipment that is approved for use in the application of Flowfresh products.
Other tools and equipment may be used as desired by the contractor and this list is not exclusive of
other sources.
Midwest Rake
PO Box 1674, Warsaw, IN 46581-1674
1-800-267-7875 www.midwestrake.com
99 Cam rakes
99 Pin and spike rollers
99 Squeegees
99 Texture (looped rollers)
99 Mohair rollers
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South Korea* Fcrete Corporation Tel: +82 2 2649 3874 Fax: +82 2 2649 3878 Email: [email protected]
Thailand Flowcrete Thailand Tel: +66 2530 9611 Fax: +66 2530 9610 Email: [email protected]
UAE Flowcrete Middle East FZCO Tel: +97 14 886 4728 Fax: +97 14 886 4582 Email: [email protected]
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*Partner Company
FCNA, 2012 V1
While every care has been taken to ensure that the information included in this document was accurate at the time of printing, Flowcrete reserves the right to change product specifications at any time without prior notice.
The photographs and colours reproduced in this publication are within the constraints of the printing process and are not to be used for matching purposes.
All photographs are used for approximate representation only and may not show the actual products on offer. E&OE.
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