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How to specify decorative epoxy flooring

The following guide contains instructions for specifying the decorative epoxy flooring system
manufactured by Real World Epoxies - Resin Rustic™


1. General

1.1 Guidelines

This specification is applicable to the Resin Rustic™ Decorative Epoxy 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 Rustic™ is a decorative, concrete epoxy floor finish specially designed for business owners or homeowners wanting the concrete look with a sleek showroom edge.

Available in 9 stunning colours, the completely seamless epoxy resin flooring system is tough, stain-resistant, easy-to-clean, and will remain a real feature for years.

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

A low-angle photo of a Resin Rustic floor in a retail outlet showing the glossy standard finish of the decorative epoxy flooring system. 

1.3 Aims

The design aim is to confirm the Resin Rustic™ 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 high-build decorative 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 Marble decorative metallic epoxy flooring system.

2.3 System Materials

First Coat - Optional Primer:

Ezypoxy Clear - Clear, 100% Solids General Purpose Epoxy

Application Method: Brush, Roller
Spread Rate: 6.67m2 per litre
Wet Film Thickness (WFT): 150 microns
Dry Film Thickness (DFT): 150 microns
Finish: Gloss
Second Coat - Basecoat:

Ezypoxy Rollcoat - Tintable, 100% Solids Epoxy Rollcoat

Application Method: Brush, Roller
Spread Rate: 5m2 per litre
Wet Film Thickness (WFT): 200 microns
Dry Film Thickness (DFT): 200 microns
Finish: Semi-gloss
Third Coat - Topcoat:

Artepoxy Liquid Crystal - Clear, 100% Solids Decorative Floor Coating, with
RWE Rustic Filler - Stir-in Aggregate Blend for Decorative Epoxy Topping

Application Method: Trowel, Squeegee
Spread Rate: 0.5m2 per litre
Wet Film Thickness (WFT): 2000 microns (2mm)
Dry Film Thickness (DFT): 2000 microns (2mm)
Finish: Gloss


Notes:

  • Practical spread rate may vary from the quoted spread rate due to factors such as application method, substrate condition etc.

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. UV Protection – An aliphatic polyurethane topcoat (Ezypoly) can be applied over the standard topcoat (Artepoxy Liquid Crystal) to provide greater UV stability and weathering performance.

  2. Matte Finish – A stir-in matting agent (Ezypoly Matte) can be used in the optional topcoat (Ezypoly) to provide a matte finish.

  3. Non-slip – A stir-in aluminium oxide particle (RWE Resin Grip Fine) can be used in the optional topcoat (Ezypoly) to provide a non-slip texture and semi-gloss finish.

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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