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Epoxy Coating & Its Properties

Epoxy Coating

Epoxy coating is a thermoset material created as a result of cross-linking epoxy, epoxy resin and a curing agent. Thermoset materials are strong and high adhesive materials that are extremely resistant to chemical agents and heat. 

Epoxy is preferred for its durable, highly adhesive, long lasting, vivid and bright finish

Epoxy Coating Properties

Since the cured application forms an extremely hard, mechanically strong film surface that is resistant to chemicals, corrosion, water and thermal fluctuations; it is perfectly suitable to be used in a variety of different sectors from space and aviation technologies to maritime fields and construction. 

Epoxy mixtures are used as floor coating, as paint, as repair mortar or as adhesives for steel reinforcement. Because of its mechanical and chemical properties, as mentioned above, it is usually preferred at heavy foot traffic areas such as floor coatings in factories, warehouse floors, aircraft hangars, parking lots, hospitals, schools and offices. 

Epoxy Coating Applications

Epoxy floor coating applications require professional workmanship in order to prevent the material from losing its properties. 

First order of business should be the careful preparation of the application surface. This requires removing any loose particles, repairing cracks with the appropriate repair mortar, removing old paints..etc. before the primer is applied. Also, the waterproofing of the application surface must be completed before the epoxy coating application. Secondly, a coat of primer must be applied on the prepared surface. Then the product must be selected in line with the desired performance on the final layer.  

The appropriate coats should be applied with the appropriate equipment depending on whether the surface will be exposed to water, whether it is an indoor or outdoor application. 

Waterproofing & Its Types

Waterproofing

Waterproofing is the process of making a structure or an area of structure water-resistant or impervious to the water seepage. 

It helps to maintain the desired level of humidity inside the said structure while protecting everything inside to the adverse effects of water and humidity. In geographies where there are high levels of annual rainfall and/or groundwater levels are higher, waterproofing foundations, basements and roofs becomes a necessity. 

Hydrostatic pressure applied by a high water table, can cause water to seep through cracks to cause structural damage as well as other troubles such as mold, mildew. 

Waterproofing methods

1-Bituminous Waterproofing

Bitumen is a petroleum product which is highly viscous, sticky and waterproof. There are two main types of bituminous waterproofing methods:

A) Bituminous membranes
B) Bituminous liquid coatings

A) Bituminous Membranes

Bituminous membranes are often hot-applied membranes (meaning they need to be heated by use of blowtorches during their application, there are other types of bituminous membranes which are self-adhesive) that are popular for low-sloped roof applications because of their proven performance through the years. 

The self-adhesive ones have low shelf lifes as the adhesive properties of this membrane lose its strength over time.

B) Bituminous Coating

Bituminous coating is a liquid waterproofing membrane. Its elastic properties and water-resistance are often modified by its polymer grade and its reinforcement of fiber. It is applied without the need of heating during its application.   

It’s an excellent protective coating and waterproofing agent, especially on surfaces like concrete foundations. It’s easy to install, provides a seamless finish, and has long term durability and wear resistance.  Bituminous coating is made from bitumen-based materials, and it usually isn’t suitable for long exposure to direct sunlight unless it’s modified using a more flexible material like polyurethane or acrylic-based polymers.

2- Polyurethane Liquid Membrane

The combination of base (polyol) and reactor (isocyanide) in a specific ratio creates a liquid coating for waterproofing applications. 

Polyurethane liquid waterproofing membranes are popular because it is one the most easy to apply waterproofing solutions out there requiring less skill and supervision during its application. It’s application and curing process is fast making it suitable for post-construction applications as well. It is extremely durable; provides a seamless finish, and has long term wear resistance. It is also extremely resistant to UV, adverse weather effects, alkaline cleaners, battery acid and fuels.

3- Cementitious Waterproofing

Cementitious waterproofing products are probably the easiest waterproofing materials to use. They are easy to procure, mix and apply. If you opt out for an acrylic additive to mix in with the cement product one will get a more solid, better bonding, and durable coating.

The chief disadvantage is that cementitious products have less flexibility compared to other types of liquid waterproofing membranes.

4- Acrylic Waterproofing

Acrylic waterproofing membranes are specialist liquids used mainly for roof coating applications. It’s suited for all types of roof applications including flat, domed, and pitched roofs. 

It’s application involves the application of a monolithic, fully bonded, liquid-based coating into a roof. The coat cures to form a rubber-like elastomeric waterproof membrane, capable of extending and returning to its original shape without damage. This type of coating applications are usually reinforced with secondary materials like glass-reinforced plastic to increase the tensile strength. This type of waterproofing  provides a cost-effective way of making a new or existing roof waterproof. 

What Are the Advantages of Using Liquid Applied Waterproofing Membranes?

A liquid applied waterproofing membrane is vital for protecting any structures. These flexible membranes can be applied by hand or by spray onto surfaces such as balconies, green roofs, foundation walls, wet volumes, etc. This type of protection can also be used to help extend the service life of structures such as car parks.

Advantages of liquid waterproofing membrane;

Liquid applied waterproofing offers number of advantages ;

Ease of application — Liquid waterproofings are very easy to apply as they do not need heating,cutting or any other extra work. Up to 100,000 square feet or 1000 square meters of coating can easily be achieved by spraying depending on the product. When applying waterproofing in more detailed or in more confined spaces these advantages become more visible.
 

Seamless — Because there are no seams or joints as liquid applied waterproofing cures to form one solid membrane, failure possibility is very very low compared to conventional hot applied waterproofing types. 

Flexibility — As by design liquid applied waterproofing products have the flexibility to expand and contract due to temperature changes or minor structural movements. This way, the waterproofing continues to perform, even when exposed to extreme weather and/or when small concrete cracks occur in the underlying structure.

Cold vs. hot waterproofing;

Before liquid applied waterproofing, general contractors relied on hot applied waterproofing because it was cheaper and  it adheres well to substrates. In today’s conditions health and safety standards are more strict and contractors may face additional permitting, have to pay extra for onsite fire marshals and/or face obstacles with securing liability insurance when using hot applied waterproofing.

Hot applied waterproofing is no longer feasible for many general contractors because there are cold applied waterproofing options available with better adhesive properties.Using cold applied waterproofing reduces the complexities and risks during construction and speeds the installation process.

What Is Cementitious Waterproofing?

Water damage in a building can become a serious issue because toxic molds and mildews may thrive and can put the entire structure at risk. A lot of residential and commercial buildings use waterproofing to prevent water seepage from happening and causing issues particularly in the basement areas. Waterproofing can also lower the energy costs and it strengthens the foundations of structures.

What Are Cementitious Waterproofing Products?

Cementitious coatings, as the name implies, rely on cement-based coatings to provide a waterproof barrier. These systems combine Portland cement with a waterproofing agent, typically a synthetic emulsion polymer. They can be applied behind tile, over masonry patching and over concrete surfaces. Cementitious coatings are popular because they’re easy to apply, create breathable barriers and offer superior bonding strength. Plus, they function equally well in both above- and below-grade applications.

Cementitious coatings can be classified either by the surface onto which they’re applied or by the number of components used in the system. In the former category, cementitious coatings can give concrete and masonry surfaces positive- and negative-side waterproofing. A positive-side surface refers to the surface exposed to positive hydrostatic pressure for example the water pushes the barrier against the structure. A negative-side surface is just the opposite for example  the water tries to pull the barrier away from the structure. On a foundation, for example, the positive-side surface would be the outside surface closest to the soil. The negative-side surface would be the inside surface of the basement wall. Cementitious coatings can also be classified as either one component or two component systems.

Advantages of cementitious waterproof coating

Cementitious waterproof coating types are two-component blends. Cementitious waterproofing method is used for substrate control movement.

Some of the advantages are;

  • It is easy to apply and it is available at any hardware store or masonry supply shops.
  • These coatings are handled similarly to cement, mix it in with water until it achieves the right consistency and can be applied using a stiff-bristled brush.
  • It is seamless and adds to the aesthetic quality of the structure it’s applied to.
  • It is chemical resistant as well as abrasion and weather resistant including frost.
  • It is good at bonding porous and non-porous surfaces, as well as old and new concrete.
  • Improves the watertightness of water-containing concrete tanks, reservoirs, and clearwells.
  • Protects against water penetration, yet water vapor permeable (breathable).
  • Excellent freeze/thaw resistance.
  • Good adhesion to sound, prepared substrates.
  • Easy and fast mixing and application.
  • Good abrasion resistance.
  • Can be mixed to slurry or trowelable consistency.
  • Improves concrete/masonry appearance.