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FLOWFRESH - antimicrobial flooring

An Installation Manual and Resource Guide

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INTRODUCTION 41. ABOUT FLOWFRESH 51.1 FLOWFRESH FLOORING GRADES 51.2 SITE STORAGE 6 1.2.1 Special Considerations 6 1.2.2 Uniform Temperature 6 1.2.3 Ideal Storage Temperatures 61.3 SHELF LIFE 61.4 COLD TEMPERATURE APPLICATION 61.5 HOT TEMPERATURE APPLICATION 71.6 SAFETY 71.7 ULTRAVIOLET AND EXTERIOR APPLICATIONS 7

2. PREPERATION OF SUBSTRATE 82.1 CONCRETE SUBSTRATES 82.2 EXPANSION & CONTRACTION JOINTS 8 2.2.1 Contraction (Control) Joints 82.3 MEMBRANE (use of Flowfresh as) 82.4 SUBSTRATES 82.5 SURFACE PREPERATION 9 2.5.1 Primary Requirements 9 2.5.2 Acceptable Methods 9 2.5.3 Surface Profile 102.6 MOISTURE 102.7 HOLES AND CRACKS 10 2.7.1 Holes, Voids and Depressions 10 2.7.2 Unapproved Materials for Patching and Filling 112.8 FLOOR FLATNESS FACTORS 112.9 SLOPE & PITCH 11

3. ALTERNATE SUBSTRATES 123.1 MILD CARBON STEEL (i.e. diamond plate) 123.2 EXTERIOR GRADE PLYWOOD 123.3 APPLICATION TO EXISTING POLYMER AND MASONRY SURFACES 12

3.4 EXISTING FLOWFRESH URETHANE CEMENT SURFACES 133.5 EXISTING MASONRY SURFACES 13

4. PRE-APPLICATION PLANNING 144.1 GOOD OPERATIONG PRACTICES 144.2 MIXING STATION 144.3 INSTALLATION PLANNING 144.4 MARGIN TREATMENTS 154.5 JOINT TREATMENT 154.6 CHAMFERING 154.7 SPECIAL CONSIDERATIONS 164.8 PRIMING AND SCRATCH COATING 16

5. MIXING OF FLOWFRESH MATERIAL 175.1 MIXING EQUIPMENT 175.2 MIXING PROCEDURE 185.3 MIXING PROBLEMS 19 5.3.1 Over-mixing 19

6. APPLICATION TOOLS 206.1 Minimum Recommended Application Equipment 20 6.1.1 Flowfresh HF & RT 20 6.1.2 Flowfresh SR/SRQ 20 6.1.3 Flowfresh MF 20 6.1.4 Flowfresh SLB 20 6.1.5 Flowfresh CM 20

7. APPENDIX 217.1 CLEANING AND MAINTENANCE 21

7.1.1 Cleaning & Maintenance 21 7.1.2 Post-installation 21 7.1.3 Service Cleaning 21 7.1.4 CIP 227.2 MAINTENANCE & REPAIR 227.3 APPROVED EQUIPMENT SOURCES 23

TABLE OF CONTENTS

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INTRODUCTIONThis 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

and Surface Texture

Components Unit Weights Standard Packaging

Thickness and Coverage (Theoretical per complete Unit)

RT Heavy Duty, Slip Resistant

Resin: White liquid Pigment pack: Blended powderHardener: Brown liquid Filler: Blended powder

Resin: 5 lb net Pigment Pack: 1 lb netHardener: 5 lb net Filler: 44 lb bag

Resin: 3 quart bottlePigment Pack: Paper bagHardener: 3 quart bottleFiller: Moisture resistant paper bag

28 Ft2 @ 3/16”21 Ft2 @ 1/4“14 Ft2 @ 3/8“

HF Heavy Duty, Slip Resistant




24 Ft2 @ 1/4 “17 Ft2 @ 3/8 “

IF Heavy Duty, Slip Resistant

Base: White liquid Pigment pack: Blended powderHardener: Brown liquid Filler: Blended powder

Base: 5 lb net Pigment Pack: 1 lb netHardener: 5 lb net Filler: 51 lb bag


14 Ft2 @ 3/8 “

SR Medium Duty, Slip Resistant




24 Ft2 @ 3/16”(1/4” system)

MF Medium Duty, Smooth




22 Ft2 @ 3/16”17 Ft2 @ 1/4”

SLB Light/Medium Duty, Slip Resistant

Base: White liquid Pigment pack: Blended powderHardener: Brown liquid Filler: Blended powder

Base: 10 lb net Pigment Pack: 1 lb netHardener: 10 lb net Filler: 40 lb bag

Resin: 1 gallon bottlePigment Pack: Paper bagHardener: 1 gallon bottleFiller: Moisture resistant paper bag

24 Ft2 @ 100mils(3/16” system)

FC Primer, (or) Lock Coat


Resin: 5 lb net Pigment Pack: 1 lb netHardener: 5 lb net Filler: 6 lb net

Resin: 3 quart bottlePigment Pack: Paper bagHardener: 3 quart bottleFiller: 1 gallon plastic pail

120 Ft2 per unit (on BCM quartz)

CM Cove Mortar Resin: White liquid Pigment pack: Blended powderHardener: Brown liquid Filler: Blended powder

Resin: 2.5 lb net Pigment Pack: 1 lb netHardener: 2.5 lb netFiller: 26 lb bag

Resin: 1/2 gallon bottlePigment Pack: Paper bagHardener: 1/2 Quart bottleFiller: Moisture resistant paper bag

11 Ft2 @ 3/16”33 ln Feet for 4 inch x 3/16” cove

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 STORAGEFlowfresh 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.

1.2.1 SPECIAL CONSIDERATIONSLiquid components: all Flowfresh liquid components are subject to freezing. Freezing of the resin or hardener components will render them unusable and unrecoverable. Protect from temperatures below 35°F (2°C) at all times. Any liquid components that have been exposed to freezing temperatures must be destroyed to prevent their use.

Filler components (quartz aggregates excepted): filler components must be protected from moisture at all times. Do not store powdered components on bare concrete floor, dirt or gravel. Store filler components in original bags on wooden or plastic pallets. Cover to prevent damage from rain or incidental water exposure. Cover stacked bags with cardboard filler before covering with plastic to prevent condensation damage.

1.2.2 UNIFORM TEMPERATURE Storage of liquids, fillers and aggregates in direct sunlight will cause uneven heating of the materials. Using components of widely differing temperatures will cause unreliable, unpredictable and non-uniform results.

ALLOW ALL COMPONENT MATERIALS TO STABLIZE TO A UNIFORM TEMPERATURE PRIOR TO USE.

1.2.3 IDEAL STORAGE TEMPERATURES The ideal storage temperature range for Flowfresh components is 65o–80°F (18o–27°C). This is the preferred temperature for material, air and substrate during application and curing. Flowfresh materials may be applied between 50o and 90°F (10o to 32oC); however, working times will be affected.

1.3 SHELF LIFE Flowfresh components have definite shelf life restrictions. Shelf life of Flowfresh materials is dependent upon storage conditions. Use of material beyond the recommended shelf life will result in unsatisfactory and unpredictable results. Material that has exceeded the factory recommended shelf life should be safely destroyed and disposed of in an environmentally responsible manner. Shelf life for all Flowfresh base and hardener is 12 months and filler is 6 months from date of manufacture.

1.4 COLD TEMPERATURE APPLICATIONInstallation of Flowfresh materials below 60°F (15°C) will present significant application issues.

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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.

1.5 HOT TEMPERATURE APPLICATIONInstallation of Flowfresh materials at temperatures above 90°F (30°C) will result in unacceptable working times that will preclude proper finishing of the product.

If temperatures above this range are expected during application of the product, some form of conditioning will be required. On small installations, icing down the material shortly before application will be effective. On larger installations, a proportionately larger capacity for cooling material will be required (Reefer truck or air-conditioned trailer).

Do not apply Flowfresh products in direct sunlight or to very hot substrates. Be aware of localized heat sources during application such as ovens, radiators, or direct sunlight through doors and windows.

Mixing times should be adjusted to allowable minimum time to allow for longer working time.

1.6 SAFETYObserve 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.

1.7 ULTRAVIOLET AND EXTERIOR APPLICATIONSFlowfresh materials of all grades (as all polyurethane concrete products) will experience color shift and fading on exposure to ultraviolet light sources and sunlight. This color shift and fading will not affect the physical performance of the product.

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2. PREPARATION OF SUBSTRATENo 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.

2.1 CONCRETE SUBSTATESConcrete substrates shall be constructed in accordance with ACI standards and practices.

2.2 EXPANSION & CONTRACTION JOINTSExpansion joints must be honored through the Flowfresh floor material and sealed with an appropriate elastomeric sealant.

All structural (Construction of “Cold” joints) must be honored through the Flowfresh topping materials.

2.2.1 CONTRACTION (CONTROL) JOINTS.Flowfresh materials may be applied directly over control joints when the concrete has cured for a minimum of 28 days at normal conditions (70°F/20°C). However, occasional cracking will occur if the joints continue to experience movement.

2.3 MEMBRANE (use of Flowfresh as)Flowfresh is not designed as a negative side water vapor or moisture barrier.

2.4 SUBSTRATESACCEPTABLE SUBSTRATES FOR FLOWFRESH FLOORINg MATERIALS

The primary considerations for acceptable substrates are:

1. Soundness2. Acceptable strength3. Surface profile

Acceptable substrates are:

1. Portland cement based concrete2. Polymer modified concrete3. High-strength repair concrete/patching/leveling materials

Unacceptable substrates are:

1. gypsum based floor leveling compounds2. Sand-cement “mud” beds3. Ceramic glazed tile (see exception for quarry below)

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2.5 SURFACE PREPERATIONSAll substrate surfaces, regardless of their composition, shall be properly prepared prior to application of the Flowfresh materials.

2.5.1 PRIMARY REQUIREMENTSRegardless of the preparation method used, the primary requirements of surface preparation shall be:

1. Clean and decontaminate the surface to remove any oil, grease, scale, biological material, or other foreign matter that will prevent proper adhesion of the topping material.

2. Remove the finish layer (laitance) of the concrete. This includes cement paste, curing agents or other surface materials that are no part of the main structural matrix of the concrete.

3. Create an aggressive open texture for the Flowfresh material to adhere to.

2.5.2 ACCEPTABLE METHODSAcceptable methods of surface preparation are:

1. Recirculation abrasive steel shot blasting.2. Scarification3. Concrete planning4. Abrasive blasting (free abrasive)5. Ultra high pressure water blasting (>25,000 psi)

Unacceptable methods of surface preparation are:

1. Low pressure water washing (<25,000 psi)2. Acid etching

a. Acid etching does not produce a uniform result.b. May cause unacceptable by-products to remain on surface.c. Produces hazardous waste by-productsd. May damage sewer drainage systems/damage sewage treatment systems.e. May damage adjacent architectural surfaces. f. May be illegal in certain environmental jurisdictions.

3. Impact Devices (scabblers)a. May fracture concrete and cause un-sound substrate condition

4. Sanding5. Flame treatments6. Polishing

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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.

2.5.3 SURFACE PROFILEAppropriate CSP Surface Profiles for various Flowfresh materials are:

Flowfresh Product Applied Thickness CSP Surface Profile

IF 3/8 inch (10mm) CSP 6 – 7

HF 1/4 inch (6mm) and greater CSP 5 - 6

HF 3/8 inch (10mm) CSP 6 – 7

SR/SRQ 3/16 inch (4.75mm) CSP 5 – 6

SR/SRQ 1/4 inch (6mm) CSP 5 - 6

MF 1/4 inch (6mm) CSP 5 - 6

SLB 100 mils CSP 4 – 5

CM 3/16 inch CSP 4 – 5

2.6 MOISTUREFlowfresh products must be applied to visibly dry concrete. Flowcrete defines “visibly dry” as:

1. No reflective film of water2. No darkening or discoloration3. 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.

2.7 HOLES AND CRACKS2.7.1 HOLES, VOIDS AND DEPRESSIONSHoles, voids and depressions in Flowfresh installations may be filled prior to topping application using approved structural filler. The following are approved materials for filling holes, voids and depressions:

1. Flowfresh HF, RT, SR or MF mixed with clean, dry pea-gravel (less than 3/8 inch average size), to an amount not to exceed 50% by volume.

2. High strength repair cements possessing the following characteristics:a. Rapid setting, minimal water load non-gypsum based repair cements.b. Minimum compressive strengths of 4,500 psi developed in under 24 hours with

ultimate compressive strength of >8,500 psi in 28 days.c. Flowcrete “Isocrete 4000” or equal.

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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.

2.8 FLOOR FLATNESS FACTORSFlowfresh floor products shall not be utilized to correct deficiencies in floor flatness of the concrete surface. Corrections to floor flatness must be made prior to the application of the Flowfresh product.

2.9 SLOPE & PITCHSlope and pitch to facilitate drainage is typically incorporated into the concrete substrate. Flowfresh materials may be used to correct minor deficiencies in slope and pitch. Flowfresh products, when properly applied, will not alter slope and pitch.

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3. ALTERNATE SUBSTRATESFlowfresh 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 cement2. Existing epoxy flooring3. Existing quarry tile and acid brick4. Exterior grade plywood5. Mild carbon steel

3.1 MILD CARBON STEEL (i.e. diamond plate)Remove all paint, coatings, grease, oil, rust and scale. Clean to comply with SSPC SP-10-Near White Blast Cleaning, SP-5-White Metal Blast Cleaning, or SP-11-Power Tool Cleaning to Bare Metal. Minimum surface profile must be 3.0 mils to assure adequate bond with Flowfresh materials.

3.2 EXTERIOR GRADE PLYWOODApplication of Flowfresh products to plywood is not normally recommended. If application to structural plywood decking is necessary, the decking shall be on exterior grade AOA rated, exposure 1 or 2, C-D-X grade, or better, span rating not less than 24 inches. The decking shall be supported on structural rated joists not more than 16 inches on center. The floor design must allow for additional dead weight of floor topping of 3 lbs per square foot. Decking shall be screwed with appropriate sized deck screws. Nails or drywall screws shall not be permitted. Joints may be pre-filled with Flowfresh MF topping. Prime surface with scratch coat of Flowfresh MF or Flowfresh FC coating and allow to completely cure prior to applying final topping. Additional expansion joints may be required depending on total temperature variations.

3.3 APPLICATION TO EXISTING POLYMER AND MASONRY SURFACESA thorough evaluation is required before a decision is made to overlay existing polymer and other floor surfaces. Flowfresh products are purpose-designed to be applied to clean, sound and properly prepared structural concrete surfaces. Any decision to apply Flowfresh materials to existing polymer or masonry surfaces should be made with due concern to soundless and condition of the substrate. An application of Flowfresh material represents a significant financial commitment and application to substrates other than recommended is best approached with caution. Application of Flowfresh materials will not correct conditions of unsoundness in masonry unit floors.

Any decision to overlay existing polymer or masonry surfaces should be predicated by evaluation of:

1. Soundness of existing substrate.

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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.

3.4 EXISTING FLOWFRESH URETHANE CEMENT SURFACESPre-existing Flowfresh or other urethane cement surfaces may be successfully recoated provided the existing surface is well bonded and sound as outlined in the previous section.

Existing Flowfresh surfaces must be prepared by mechanical scarification utilizing a rotary scarifier (Von Arx, or equal). ABRASIVE STEEL SHOT BLASTINg (“blastrac” or similar) IS NOT AN ACCEPTABLE METHOD OF PREPARATION.

3.5 EXISTING MASONRY SURFACESMasonry surfaces (quarry/dairy tile, acid brick) should be prepared by abrasive shot blasting. Floor surface shall be inspected thoroughly after preparation to evaluate adhesion of grout lines. Prepared tile or brick surfaces shall have a uniform rough finish with all glaze removed from the surface.

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4. PRE-APPLICATION PLANNING

4.1 GOOD OPERATIING PRACTICESThe 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.

4.2 MIXING STATIONProvide for adequate area to mix the product. Consideration should be made for the disposal of empty containers that will accumulate during mixing. Provide additional labor to handle the disposal of containers so as not to interrupt the movement of material to the mix station, mixing and movement of mixed material to the application area.

Provide protection of the floor under and around the mix station to prevent contamination of the concrete surface underneath. Plastic sheeting (min. 6 mil) in double sheet with cardboard underneath should be placed to protect the floor around the mixing station.

Protect the floor areas in between the mix station and the application area. Any spilled material must be cleaned up to prevent out-gassing and bubbling of material placed on top of it. Place plastic sheet, cardboard, or rosin paper on material path to prevent spilled material from contacting the prepared concrete prior to application. Pull the covering back as the application progresses.

4.3 INSTALLATION PLANNINGPrior 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.

4.4 MARGIN TREATMENTSMasking should be performed on any areas that would be damaged by coming in contact with wet Flowfresh materials. Walls, columns, doors, casework, electrical equipment, plumbing, windows should all be examined and provisions for masking or covering should be made.

Through-floor penetrations should be examined to insure that material does not flow into floors or spaces below. Seal with foam backer rod as required.

4.5 JOINT TREATMENTPrior to installation all joints, expansion, control and construction, should be cleaned with a masonry saw, blown out with compressed air or vacuumed to remove dust and debris.

Expansion joints should be open and clear of asphalted fiberboard or cork filler board. Fill with closed-cell foam backer rod.

Contraction (control) joints should be cleaned and filled with appropriate size closed-cell foam backer rod. Treat as outlined in the section covering joints.

Construction (cold) joints need to be honored and reflected through the Flowfresh topping. Normally, this type of joint is closed and indicates where on structural pour stops and another begins, and is installed without the benefit of an expansion joint. Construction joints should be marked prior to Flowfresh installation with a nail or other method, and re-sawed after installation of the topping.

4.6 CHAMFERINGIdentify 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 trenches2. Terminations to same level adjacent floor3. Doorways, transoms, overhead doors

Treat these terminations in accordance with the construction details contained elsewhere in this document.

4.7 SPECIAL CONSIDERATIONSCarefully examine and discuss with the owner or engineer any special conditions that may exist after the floor is put into service. Examples of areas that should receive special consideration are:

1. Areas where process temperatures may reach the practical limits of the Flowfresh material.2. Areas where point sources of very high, or continuous temperatures may exist.

a. Steam condensate down-pipes in close proximity to the floor surface should be shielded from the Flowfresh surface with a piece of steel, or a piece of quarry tile.

b. Burners under cooling vessels should be shielded.c. Oil drains from frying or cooling vessels should be piped through and not allowed to purge

on to the floor surface at temperatures above the recommended limit for the selected material. 3. Areas where the total temperature change will be extraordinary. Freezer cases and flash

freezers where the differences between the application temperature and the operation temperature will be in excess of 20°F (-6oC) need to be evaluated for areas of restrained expansion or contraction. Extraordinary reduction in temperature after application can be successfully achieved if the proper allowance is made for the reduction in dimension cause by thermal contraction. Consult Flowcrete Technical Service for assistance.

4.8 PRIMING AND SCRATCH COATINGSurface defects in the prepared substrate and excessive surface texture from scarification may reflect through the finished Flowfresh topping. In cases where excessive texture is produced from aggressive preparation and/or surface removal, a scratch coat of Flowfresh MF may be recommended.

Under certain environmental conditions, out-gassing of the concrete may cause surface defects in the finished Flowfresh topping and priming of the concrete surface may be required. These conditions may include:

1. Rapidly rising temperatures2. Heavily air conditioned interior environments

Flowfresh IF, HF, RT, SR SRQ & SLB do not normally require a primer due to their application method unless the substrate is extremely porous.

Flowfresh MF when applied as a smooth finish will require a primer coat prior to application. Flowprime is normally used as a primer; Flowfresh FC can also be used in areas of high heat. A scratch coat of Flowfresh MF may also be used as a primer. Any primer coat must be allowed to cure prior to installation of the final Flowfresh product.

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5. MIXING OF FLOWFRESH MATERIALNo 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 cure2. Poor adhesion3. Uneven coloration and surface texture4. 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.

5.1 MIXING EQUIPMENTFlowfresh materials are heavy-bodied, viscous materials that require robust mixing equipment. Use of mixing equipment that is inadequate for the job will result in uneven mixing of the product. In addition, inadequate mixing equipment may fail during installation and cause compound problems with the installation process. HAND MIXINg IS UNACCEPTABLE IN ALL CASES AND WILL VOID WARRANTY.

Mixing of Flowfresh FC and MF products may be accomplished with a heavy duty ½ inch minimum chuck and appropriate mixing attachment.

There are many types of mixing devices on the market that are adequate for mixing Flowfresh materials. These machines all have the following in common:

1. Electric motors with robust gear drives. Exposed chain drives are not recommended.2. Electric motors of at least 1 hp3. Side and bottom scraping paddles4. Capacity of at least 1 cu. feet

A list of approved mixers follows in the appendix.

Ensure that any mixing equipment is clean and in good repair. Follow all OSHA, state and local safety regulations regarding electrical equipment, cords and safety covers. Do not operate any mixing equipment unless a daily safety inspection has been performed.

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5.2 MIXING PROCEDUREDo 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 PROBLEMS5.3.1 OVER-MIXINGBe 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 TOOLSSuccessful 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. MINIMUM RECOMMENDED APPLICATION EQUIPMENTThe minimum recommended application equipment for each Flowfresh product is:

6.1.1 FLOWFRESH IF, HF & RT1. Finishing trowels2. Screed box3. Roller Frames and Mohair Covers

6.1.2 FLOWFRESH SR/SRQ1. Screed ‘pin’ or ‘cam’ rake with thickness adjustment2. Finishing trowels3. Porcupine, spike or loop rollers4. Roller frames and covers for topcoat

6.1.3 FLOWFRESH MF1. Screed ‘pin’ or ‘cam’ rake with thickness adjustment2. Porcupine or spike rollers

6.1.4 FLOWFRESH SLB1. 1/2” Notched Squeegee

2. Porcupine or spike rollers

6.1.5 FLOWFRESH CM1. Cove base forming trowels (gutter tool)

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7. APPENDIX

7.1 CLEANING AND MAINTENANCE7.1.1 CLEANING AND MAINTENANCEFlowfresh 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-INSTALLATIONCleaning 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.

7.1.3 SERVICE CLEANINGAfter the Flowfresh floor has been put into service, normal plant cleaning procedures may be employed.

There are no effective restrictions on the method of cleaning employed. The method of cleaning should match the soil conditions and degree of sanitation required. Flowfresh products, when properly installed, will withstand water wash down at continuous sanitizing temperatures (>180°F/>82oC). Flowfresh HF, when properly installed, will withstand routine cleaning by direct application of water-steam mix.

Routine fumigation will not affect Flowfresh products.

Contact your local cleaning materials manufacturer or distributor for recommendations on the proper cleaning materials suitable for your application.

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7.1.4 CIPSome 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 Acid3. Phosphoric Acid4. “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.

7.2 MAINTENANCE AND REPAIREven the most carefully installed and maintained Flowfresh floor will sometimes be damaged by excessive force from dropped objects, construction/plumbing modifications, and excessive chemical exposure. In addition, expansion joints must be considered a maintenance item, subject to routine inspection and repair as required. It is accepted that most large floor failures begin as small failures that are usually easily and inexpensively repaired.

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7.3 APPROVED EQUIPMENT SOURCESThe 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.

Ted Baugh Flooring, Inc. PO Box 741, Carthage, MO 64836

417-358-0708 www.tedbaugh.com

9 Screed boxes 9 Mortar Mixers

Whitecap Construction Supply Locations throughout U.S.

1-800-whitecap www.whitecap.net

9 Ardex smoothing tools

Midwest Rake PO Box 1674, Warsaw, IN 46581-1674

1-800-267-7875 www.midwestrake.com

9 Cam rakes 9 Pin and spike rollers 9 Squeegees 9 Texture (looped rollers) 9 Mohair rollers

The Wooster Brush Company 604 Madison Avenue, PO Box 6010 Wooster, Ohio 44691-6010

800-392-7246 www.woosterbrush.com

9 Texture (loop) rollers 9 Paint rollers

Man-U-Fab Inc. 3025 Bailey Road, Newport, MN 55055

651-458-1768 [email protected]

9 Mortar mixers

www.flowcrete.us

www.flowcrete.usAn Company www.flowcrete.us

Flowcrete around the worldManufacturing Centres

UK Flowcrete UK Ltd Tel: +44 1270 753 000 Fax: +44 1270 753 333 Email: [email protected] Flowcrete Sweden AB Tel: +46 42 600 07 00 Fax: +46 42 15 50 90 Email: [email protected] Flowcrete India Pvt Ltd Tel: +91 44 4202 9831 Fax: +91 44 4202 9832 Email: [email protected] Flowcrete Asia Sdn Bhd Tel: +60 3 6277 9575 Fax: +60 3 6277 4645 Email: [email protected] Africa Flowcrete SA (Pty) Ltd Tel: +27 31 461 3411 Fax: +27 31 461 3475 Email: [email protected] Flowcrete North America Inc. Tel: +1 936 539 6700 Fax: +1 936 539 6701 Email: [email protected] Flowcrete Belgium Tel: +32 157 569 27 Fax: +32 157 528 94 Email: [email protected]

Sales Centres

Australia Flowcrete Australia Pty Ltd Tel: +61 7 3205 7115 Fax: +61 7 3205 3116 Email: [email protected] States Flowcrete Baltics Tel: +37 1 2864 4666 Fax: +48 22 879 8918 Email: [email protected]* Flowcrete Canada Tel: +1 936 539 6700 Fax: +1 936 539 6701 Email: [email protected] Flowcrete China Tel: +86 10 8472 1912 Fax: +86 10 8472 1942 Email: [email protected] Flowcrete Sweden AB Tel: +45 3155 7882 Fax: +46 42 15 50 90 Email: [email protected] Flowcrete France SAS Tel: +33 344 588 976 Fax: +33 344 587 386 Email: [email protected] Kong Flowcrete (Hong Kong) Ltd Tel: +852 2795 0478 Fax: +852 2795 4842 Email: [email protected] Flowcrete Indonesia Tel: +62 21 252 3201 Fax: +62 21 252 0720 Email: [email protected]* Flowcrete Mexico Tel: +1 936 539 6700 Fax: +1 936 539 6701 Email: [email protected] Flowcrete Norway AS Tel: +47 6486 0830 Fax: +47 6486 0831 Email: [email protected] Flowcrete Polska Sp. z.o.o. Tel: +48 22 879 8907 Fax: +48 22 879 8918 Email: [email protected]* S.C. Flowcrete Romania s.r. Tel: +40 374 00 80 78 Fax: +40 21 255 03 15 Email: [email protected]* Flowcrete RUS Tel: +7 (495) 645 83 18 Fax: +7 (495) 645 83 18 Email: [email protected] Korea* Fcrete Corporation Tel: +82 2 2649 3874 Fax: +82 2 2649 3878 Email: [email protected] Flowcrete Thailand Tel: +66 2530 9611 Fax: +66 2530 9610 Email: [email protected] Flowcrete Middle East FZCO Tel: +97 14 886 4728 Fax: +97 14 886 4582 Email: [email protected] Vietnam Flowcrete Vietnam Tel: +84 8 38216561 Fax: +84 8 3821 6501 Email: [email protected]

*Partner Company

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.

Norway

DenmarkSweden

UK

Russia

France

Malaysia

Thailand

VietnamPoland

South Africa

Hong Kong

Australia

UAE

China

Belgium

IndiaRomania

USA

South Korea

Canada

Mexico

Baltic States

Indonesia

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