Duraguard Protective Coating Solutions
Commercial & Industrial Concrete Floor Systems & polishing
Preparation Method
There are many factors that can affect the adhesion and bonding capabilities of a polymer system to the substrate. In order to achieve optimum adhesion, the sustrate must be clean and prepared properly. Therefore, it is ultimately necessary and absolutely important to check the conditions of the substrate in order to correctly identify the proper and correct method of preparation.
The preferred method of concrete surface preparation is by use of an abrasive shot-blasting machine, on all horizontal surfaces. Chemical preparation, although acceptable and commonly used, is a less desirable method of surface preparation due to potential for insufficient recovery of the cleaning solutions and the surface being left un-abraded. Shot-blasting of a concrete substrate is by far the most effective surface preparation technique available; both from a cost and environmental standpoint.
A highly effective method of surface preparation used prior to the application of coatings, sealers or overlays to a substrate. Shot-blasting not only cleans a surface by removing surface contaminants, it provides a surface profile which will allow for the best adhesion of the coating or overlay. Shot-blasting is the preferred method of surface preparation for several reasons:
- Shot-blasting is a one-step method that will strip, clean and profile a surface.
- Shot-blasting is a dust-free operation, using self-contained dust collectors thus making it ideal for sensitive environments.
- Shot-blasting does not use chemicals, therefore there is no post-cleanup and no hazardous material use.
- Shot-blasting is faster than other methods. Substrate is ready for coating immediately after blasting.
- Shot-blasting does not impregnate perticulate into the surface.
Special Considerations
Condition of Concrete — Newly placed portland cement concrete (PCC) is designed to develop its full strength typically in 28 days, at which time a polymer system can be applied. A light steel troweled finish is most desirable. Existing concrete should be structurally sound an devoid of any detrimental materials and any surface contaminates.
Surface Contaminates — These include a variety of foreign compounds including; curing compounds, release agents, hardeners, grease, oils, food by-products, chemicals, fatty acids, old coatings, dust and dirt.
Concrete surface preparation in Wisconsin is the foundation of every successful floor coating installation by Duraguard Protective Coating Solutions. Proper substrate preparation is the single most critical factor in floor coating performance — more coating failures are caused by inadequate surface preparation than any other factor.
Why Surface Preparation Matters
A floor coating system is only as good as the surface it’s applied to. Contaminated, weak, or improperly prepared concrete will cause even the highest quality coating to fail prematurely through delamination, bubbling, or cracking. Duraguard’s commitment to proper surface preparation is what separates our installations from those of less experienced contractors.
Surface Preparation Methods We Use
Shot Blasting — The industry standard for preparing concrete floors for coating. Shot blasting mechanically profiles the concrete surface creating the anchor pattern necessary for proper coating adhesion. Duraguard uses self-contained shot blast equipment that captures dust and debris during the process.
Diamond Grinding — Used for smoothing high spots, removing existing coatings, and preparing surfaces where shot blasting is not practical. Diamond grinding produces a clean, profiled surface ready for coating application.
Scarifying — Heavy duty mechanical preparation for severely contaminated or deteriorated concrete surfaces requiring aggressive material removal.
Acid Etching — Chemical surface preparation method used in specific applications where mechanical preparation is not feasible.
Quality Testing Procedures
Duraguard performs comprehensive quality testing before, during, and after every floor coating installation to ensure long-term performance:
Moisture Testing — Concrete moisture content is tested using calcium chloride and relative humidity testing methods before any coating is applied. Excess moisture is the leading cause of coating failure and must be identified and addressed before installation begins.
Surface Profile Testing — The concrete surface profile is measured to ensure proper anchor pattern for coating adhesion per ICRI guidelines.
Pull-Off Adhesion Testing — After installation, adhesion testing confirms the coating has properly bonded to the substrate.
Compressive Strength Testing — Concrete compressive strength is verified to ensure the substrate can support the intended coating system and traffic loads.
The Duraguard Difference
Many floor coating contractors skip proper surface preparation to save time and money. Duraguard never cuts corners on prep work. Our 30-year track record of successful installations across Wisconsin and Northern Illinois is built on doing the job right from the ground up — starting with proper surface preparation and quality testing on every project.
Get a Free Quote for Your Wisconsin Facility
Contact Duraguard today to discuss your floor coating project. We serve industrial and commercial facilities throughout SE Wisconsin and Northern Illinois within an 80-mile radius of our Racine headquarters.
Moisture — To achieve proper adhesion of the polymer system, repairs and or additional coatings may be necessary to eliminate the movement of water and vapors through the substrate.
Evaluation Factors
Repairs of surface irregularities (including cracks, delamination, deteriorated joints, pitching for drainage, etc. ) can be accomplished after the surface preparation is complete, and must be done prior to application of the polymer system. Dura-Guard offers several products for patching and crack repair. These repairs should be appropriate and consistent with the system and method of application that will be used.