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How to specify commercial kitchen epoxy flooring

The following guide contains instructions for specifying the high-build, non-slip epoxy flooring system
manufactured by Real World Epoxies - Resin Rock™


1. General

1.1 Guidelines

This specification is applicable to the Resin Rock™ High-build Non-slip Flooring System manufactured and supplied by Real World Epoxies (RWE) Pty Ltd.

This work section should be read in conjunction with installation and maintenance guides for the system.

1.2 System Description

Resin Rock™ is a high-build, non-slip flooring system specially designed to rebuild and resurface rough, worn or damaged floors in commercial kitchens and processing areas.

Available in all Australian Standard colours, the completely seamless resin flooring system can be applied in all conditions, and is resistant to wear, heat, chemicals and impact.

Most importantly, Resin Rock™ has no strong smell and contains no solvents or flammables, so it can be installed safely without risk or disruption to your workers or business.

A low-angle photo of a Resin Rock floor in a commercial kitchen showing the textured finish of the high-build, non-slip epoxy system. 

1.3 Aims

The design aim is to confirm the Resin Rock™ flooring system - standard or with the available options - can satisfy the client’s functional and decorative intention, as well as suit the expected service and maintenance demands of the flooring area.

1.4 Quality Assurance

1.4.1 Products

The products used should be Real World Epoxies products, supplied in their original containers with product code, batch code and other markings clearly visible.

1.4.2 Installer

Must be a licensed resin flooring installer (where applicable), with proven experience in the application of trowel-down and broadcast flooring systems.

1.4.3 Pre-contract Meeting

All parties must conduct pre-contract meeting to confirm project requirements, substrate conditions, manufacturer’s specification and warranty requirements.

1.5 Submissions

1.5.1 Samples

A labelled sample of the system on plywood, MDF or similar surface must be submitted before project commencement, clearly showing the colour and surface finish. Minimum size allowed is A4.

1.5.2 Product Data

The current editions of the manufacturer’s product literature, including relevant testing and certification, technical data sheets (TDS), safety data sheets (SDS), and application/installation instructions.

1.5.3 Warranties

Manufacturer’s product warranty/guarantee should be submitted, as well as the workmanship warranty offered by the installer.

2. Products

2.1 Manufacturer

Real World Epoxies Pty. Ltd.
19/10 Miltiadis St
Acacia Ridge
QLD 4110
PH: 1300 EPOXIES

2.2 System Diagrams

A diagram showing the different products and coats used to form the Resin Rock high-build non-slip flooring system.

2.3 System Materials

First Coat - Basecoat:

Ezypoxy Clear - Clear, 100% Solids General Purpose Epoxy, with
RWE Slurry Mix - Stir-in Aggregate Blend for Slurry Mixture

Application Method: Trowel
Spread Rate: 0.5m2 per litre
Wet Film Thickness (WFT): 2000 microns (2mm)
Dry Film Thickness (DFT): 2000 microns (2mm)
Finish: Gloss
Second Coat - Non-slip:

RWE Resin Grip HD – Broadcast Aggregate for Non-slip Flooring

Application Method: Hand, Broadcast Machine
Spread Rate: 0.25-0.3m2 per kg
Wet Film Thickness (WFT): -
Dry Film Thickness (DFT): -
Finish: -
Fourth Coat - Topcoat:

Ezypoxy Rollcoat - Tintable, 100% Solids Epoxy Rollcoat

Application Method: Brush, Roller
Spread Rate: 4m2 per litre
Wet Film Thickness (WFT): 250 microns
Dry Film Thickness (DFT): 250 microns
Finish: Semi-gloss


Notes:

  • While the basecoat is applied at 2mm, the overall thickness of the standard flooring system is approximately 4mm once the non-slip particle has been broadcast and the topcoat applied.
  • Practical spread rate may vary from the quoted spread rate due to factors such as application method, substrate condition etc.
  • Although the topcoat is semi-gloss, the highly textured surface of the standard system creates a fully matted finish.
  • The extra surface area created by the texture may require vigorous rolling to fully coat all the particles. Thicker films than the minimum 250 microns can be applied but will result
    in a less aggressive non-slip profile.

3. Execution

3.1 Inspection

Prior to commencement of work, arrangements should be made to conduct an examination of the floor area to be coated. Notes concerning the prevailing conditions should be taken along with photos of the site, and issues addressed during pre-contract meeting (Section 1.2.3). Do not proceed with the work until all conditions have been met to the satisfaction of all parties.

3.2 Preparation

3.2.1 Fixtures

Remove strips, transitions, skirting boards, door stops, drain covers and other fixtures where possible, and re-fix in position upon completion of the installation.

3.2.2 Concrete

New concrete surfaces should be allowed to cure for a minimum of 28 days.

Contaminated concrete surfaces should be degreased with a suitable detergent prior to surface preparation.

Small static cracks, chips, divots and other minor imperfections should be patched with Ezypoxy Clear with RWE Ezypatch filler.

Checks and measures should be taken to ensure the subfloor should not deviate more than the following distances under a straight edge tool (as per Australian Standard AS 1884-2012):

  • 4mm over 2m (flatness).
  • 1mm over 150mm (smoothness).
  • 0.5mm over 50mm (projections).

Diamond grind or shot blast to obtain a CSP 2-3.

Properly prepared surfaces should be structurally sound and free of contamination, laitance and any loose material.

Ensure surface is clean, dry and dust-free again if there’s a delay between preparation and application.

3.2.3 Porous Surfaces

If the concrete is found to be weak, powdery or porous during preparation, a primer coat of Ezypoxy Clear should be applied first.

3.2.4 Coated Surfaces

Maximum delay between coats is 36 hours @ 25oC. Should this time be exceeded the previous coat must be lightly abraded with 80-120 grit paper, vacuumed and wiped with methylated spirits or other suitable solvent.

Old, existing films can be over-coated providing they’re in good condition and there are no adhesion issues. If in doubt, a tensile adhesion test should be conducted.

3.2.5 Joints

Control joints can be in-filled prior to system installation if preferred by the client, e.g. aiming for a seamless finish. It should be made clear, however, rigid materials such as this resin flooring system are at greater risk of developing cracks in these areas.

Provide movement joints as follows:

  • Over structural (isolation, contraction, expansion) joints.
  • At junctions between different substrates.

Where possible, carry the seamless finish material over the edges of the control joint in the substrate. Provide a sealant joint as follows:

  • Sealant width: 6-25mm.
  • Sealant depth: One half of the joint width, or 6mm, whichever is the greater.
  • Sealant: Two-pack, self-levelling, non-hardening, mould-resistant polyurethane sealant applied over a backing rod. Finish flush with the surface.
  • Trafficable floors: Shore hardness >35.
  • Backing rod: Compressible, closed-cell polyethylene foam with a bond-breaking surface.

Diamond grind or shot blast to obtain a CSP 2-3.

Properly prepared surfaces should be structurally sound and free of contamination, laitance and any loose material.

Ensure surface is clean, dry and dust-free again if there’s a delay between preparation and application.

3.2.6 Coving

If required, coving can be installed prior to system installation using Ezypoxy Clear with RWE Cove Mix and a coving tool of suitable radius.

3.3 Installation

3.3.1 System Installation

Apply selected design in accordance with specification in Materials (Section 2.2) and manufacturer’s installation guide.

3.3.2 Options/Extras

The standard system can be modified to achieve the following:

  1. Reduced Slip Rating – A lower concentration of non-slip particle and/or a finer particle can be used to reduce the non-slip profile and make the surface easier to clean.

  2. Extra Moisture and Chemical Resistance – The Jaxxon brand of heavy-duty industrial coatings can be substituted for the basecoat (Jaxxon 1335) and topcoat (Jaxxon 1505) to offer enhanced resistance in harsh conditions.

3.4 Completion

Light traffic can resume 24 hours after the final coat has been applied. Full service can be restored after 7 days.

A handover meeting should be conducted within the first 24 hours to identify areas that may need repair or replacement. This should involve the review and official submission of daily records collected by the installer. Once all parties are satisfied with the work done, signatures should be given to indicate official acceptance of the project.

The manufacturer’s published floor maintenance instructions should be submitted to the client if not already done so.


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