Benefits

Dur-A-Quartz™ Epoxy Flooring offers numerous benefits, making it a superior choice for industrial and commercial spaces. Its seamless, non-porous surface provides excellent resistance to chemicals, moisture, and heavy wear, ensuring long-lasting durability. The system is ideal for restoring old floors to a better-than-new condition, enhancing both functionality and aesthetics. With a wide range of color options, it allows for a customized appearance that suits various environments. The integral cove base design prevents water accumulation, reducing the risk of damage and making cleaning easier. Additionally, the flooring is resistant to food and chemical spills, making it perfect for food processing, healthcare, and industrial facilities. The high-quality epoxy resin and quartz aggregate ensure a strong bond with the substrate, minimizing the risk of delamination. The system also meets ASTM standards for hardness, compressive strength, and tensile strength, ensuring reliability and performance. Overall, Dur-A-Quartz™ Epoxy Flooring is a cost-effective solution that combines durability, aesthetics, and low maintenance, providing a long-lasting and protective surface for demanding environments.

Surface Preparation

Proper surface preparation is critical for a successful Dur-A-Quartz™ installation. Ensure the concrete is cured for at least 28 days and has less than 3% moisture content. Mechanically prepare the surface to remove contaminants and achieve the required profile for optimal bonding. A vapor barrier may be necessary if moisture levels are high.

Cleaning the Surface

Cleaning the surface is a critical step in preparing for Dur-A-Quartz™ application. The substrate must be free of dirt, oil, grease, and other contaminants to ensure proper adhesion. Begin by sweeping or blowing the surface with compressed air to remove loose debris. For more thorough cleaning, use a degreaser or industrial cleaner, scrubbing the surface thoroughly before rinsing with clean water. Allow the surface to dry completely. Any existing coatings or old adhesives must be removed mechanically or through chemical stripping. The surface should also be checked for efflorescence or laitance, which must be removed to ensure a strong bond. Finally, ensure the surface is profiled correctly to meet the manufacturer’s requirements for optimal bonding. Proper cleaning and preparation are essential for a durable and long-lasting Dur-A-Quartz™ installation.

Moisture Testing

Moisture testing is a critical step in the Dur-A-Quartz™ application process to ensure the substrate is suitable for installation. High moisture levels can lead to adhesion issues and system failure. Use a Tramex Concrete Moisture Encounter Meter to measure moisture vapor transmission (MVT) rates. The substrate must have a moisture content of less than 3% as per ASTM-1864 standards. If the reading exceeds acceptable levels, a moisture vapor barrier must be applied before proceeding with the installation. This step is essential to prevent future delamination and ensure a strong bond between the epoxy system and the concrete. Additionally, the substrate should be free of hydrostatic pressure and capillary action, which can compromise the integrity of the flooring system. Proper moisture testing ensures a stable and durable installation, adhering to the manufacturer’s specifications and industry standards. Always follow the manufacturer’s guidelines for moisture testing to achieve optimal results.

Repairing Damaged Areas

Before applying Dur-A-Quartz™, any damaged areas on the concrete substrate must be repaired to ensure a stable and even surface. Cracks, pits, and spalled areas should be addressed using a suitable epoxy-based repair compound. The damaged areas must be mechanically prepared to remove loose or deteriorated material, ensuring a clean and rough surface for proper bonding. Once repaired, the areas should be allowed to cure as per the manufacturer’s instructions.

For areas requiring more extensive repair, such as those not ending at a construction joint, the edges should be cut and keyed to a minimum depth of 1/4 inch to ensure adequate bonding. This step is critical to prevent weak points in the final system; After repairs, the surface should be thoroughly cleaned and dried before proceeding with the installation of the Dur-A-Quartz™ system. Properly addressing damaged areas ensures a seamless and durable finish, preventing future issues such as delamination or uneven wear. Always follow the manufacturer’s guidelines for repair materials and methods to achieve optimal results.

Applying a Primer

Applying a primer is a critical step in the Dur-A-Quartz™ installation process, ensuring proper adhesion and durability of the flooring system. The primer used is typically a two-component, 100% solids epoxy, such as Dur-A-Glaze 4, which is specifically formulated to bond with the concrete substrate and the subsequent layers of the system.

The primer should be mixed according to the manufacturer’s instructions and applied evenly to the prepared surface using a squeegee or roller. It is essential to follow the recommended coverage rate to achieve a uniform film thickness. Once applied, the primer must be allowed to cure as specified, usually overnight, before proceeding with the trowel application of the Dur-A-Quartz™ mixture.

Proper priming ensures a strong bond between the concrete and the epoxy-quartz system, reducing the risk of delamination and extending the lifespan of the flooring. Always adhere to the manufacturer’s guidelines for primer application to achieve optimal results.

Application Steps

The application of Dur-A-Quartz™ involves several key steps, including mixing the epoxy, troweling the mixture, broadcasting quartz aggregate, applying a grout coat, and finishing with a topcoat. Each step requires careful attention to manufacturer instructions and proper curing times to ensure a durable, seamless finish.

Mixing the Epoxy

Mixing the epoxy is a critical step in the Dur-A-Quartz™ application process. The system consists of a two-component, 100% solids epoxy resin, which must be mixed according to the manufacturer’s instructions. Ensure the components are at room temperature (between 60°F and 90°F) before mixing to prevent curing issues. Use a prepackaged kit to maintain the correct resin-to-hardener ratio, as deviations can affect performance. Mix thoroughly for 2-3 minutes using a low-speed drill with a mixing paddle until the mixture is uniform and free of streaks. Avoid overmixing, as this can introduce air bubbles. Once mixed, the epoxy has a limited working time, so apply it immediately to the prepared surface. If delays occur, consult the manufacturer’s guidelines for potential extensions. Proper mixing ensures a strong bond and a durable, seamless finish. Always wear protective gear, including gloves and goggles, when handling epoxy materials. If unsure about the mixing process, contact Dur-A-Flex’s technical support for assistance. Proper mixing is essential for achieving the desired results with Dur-A-Quartz™ epoxy flooring.

Troweling the Mixture

Troweling the Dur-A-Quartz™ epoxy mixture is a precise process that ensures a smooth, even, and durable surface. Once the epoxy is properly mixed, it should be applied immediately to the prepared surface using a notched trowel. Work in small, manageable sections to maintain control and consistency. Hold the trowel at a 45-degree angle and apply firm, even pressure to spread the mixture uniformly. This technique helps prevent air bubbles and ensures proper adhesion to the substrate.

Use long, overlapping strokes to cover the area thoroughly, feathering the edges to blend seamlessly with adjacent sections. Avoid overworking the mixture, as this can introduce air pockets or pull material from previously applied areas. The epoxy should be applied to a thickness of approximately 1/4 inch, as specified by the manufacturer. If necessary, use a leveling tool to achieve the desired finish. Always work in the direction of the aggregate broadcast to ensure proper orientation and bonding. The troweling process must be completed before the epoxy begins to cure, so timing is critical. For best results, use a torch or flashlight to inspect the surface for air bubbles and address them immediately. Proper troweling is essential for achieving a professional-grade, long-lasting Dur-A-Quartz™ floor.

Broadcasting Quartz Aggregate

Broadcasting quartz aggregate is a critical step in the Dur-A-Quartz™ application process, ensuring a decorative and durable finish. Immediately after troweling the epoxy mixture, evenly broadcast the Q28 or Q11 colored quartz aggregate over the wet surface. Use a broadcast spreader or throw the aggregate by hand, working in sections to cover the entire area thoroughly. The goal is to achieve full coverage, known as “broadcast to rejection,” where no epoxy is visible beneath the aggregate.

Allow the mixture to cure until it reaches a tacky state, typically within 24 hours, before removing excess quartz. Use a stiff broom or brush to sweep off loose particles, ensuring the surface is even and properly bonded. Lightly sand the area to smooth out any unevenness or excess aggregate. This step is essential for achieving a seamless, professional-grade finish. Proper broadcasting ensures the quartz aggregate is securely embedded in the epoxy, providing long-lasting durability and aesthetic appeal. Timing is crucial, as the epoxy must still be wet to bond effectively with the aggregate. Avoid over-broadcasting, as this can lead to a thick, uneven surface. The result is a decorative, high-performance floor designed to withstand heavy use and chemical exposure.

Applying the Grout Coat

After broadcasting and curing the quartz aggregate, the next step is applying the grout coat. This process involves using a high-quality, 100% solids epoxy resin, such as Dur-A-Glaze 4, to fill the spaces between the quartz particles. The grout coat ensures a smooth, even surface and enhances the floor’s durability and appearance.

To apply the grout coat, use a squeegee to spread the epoxy mixture evenly across the floor. Immediately back-roll the surface using a roller to achieve uniform coverage and texture. For areas around columns, walls, and other obstacles, use smaller rollers or brushes to ensure proper application. It’s crucial to follow the manufacturer’s instructions for mixing and application rates to avoid over- or under-application.

The grout coat should cure according to the manufacturer’s specifications, typically overnight, before proceeding to the final topcoat. This step is essential for creating a seamless, professional-grade finish. Proper application ensures the quartz aggregate is fully encapsulated, resulting in a durable, chemical-resistant surface. Always adhere to the recommended curing times and conditions to achieve optimal results.

Finishing with a Topcoat

After the grout coat has cured, the final step is applying a durable topcoat to protect the surface and enhance its appearance. A high-performance, two-component urethane such as PolyThane 2 HS is typically used for this purpose. The topcoat is applied using a squeegee and back-rolled to ensure even coverage and texture consistency across the floor.

For areas around columns, walls, and obstacles, smaller rollers or brushes are used to ensure proper application. The topcoat cures according to the manufacturer’s specifications, usually requiring a minimum of 16 to 30 hours before full physical use. During this time, the floor must be protected from foot traffic and contaminants to ensure a proper cure.

Once cured, the topcoat provides excellent chemical resistance and durability, making the floor suitable for heavy-duty industrial and commercial environments. It’s important to maintain the recommended curing temperature (65-90°F) and avoid exposure to moisture during the curing process. The topcoat completes the Dur-A-Quartz system, delivering a seamless, professional-grade finish.

Maintenance and Care

Proper maintenance is essential to ensure the longevity and performance of Dur-A-Quartz epoxy flooring. Regular cleaning with manufacturer-recommended materials is crucial to prevent dirt and contaminants from damaging the surface. Avoid using harsh chemicals or abrasive cleaners, as they may degrade the topcoat or harm the epoxy resin.

For spills, especially chemicals, clean them immediately to prevent damage. Once fully cured (after 7 days), the floor achieves full chemical resistance. Protect the floor from heavy equipment or sharp objects that could scratch or chip the surface. During the curing process (10-12 hours for foot traffic, 16-30 hours for full use), keep the area at 65-90°F and avoid exposure to moisture.

Regular inspections can help identify potential issues early, such as wear or damage, which can be addressed before they escalate. Annual deep cleaning and periodic touch-ups are recommended to maintain the floor’s appearance and functionality. By following these care guidelines, Dur-A-Quartz flooring will remain durable, attractive, and resistant to industrial and commercial demands for years.

Safety Precautions

When working with Dur-A-Quartz epoxy flooring, it is essential to follow safety guidelines to ensure a safe installation process. Always read and understand the Safety Data Sheet (SDS) for the epoxy and quartz aggregate before starting the project. Wear appropriate personal protective equipment (PPE), including gloves, safety goggles, and a dust mask, to protect against skin and eye irritation and inhalation of dust or fumes.

Ensure good ventilation in the work area to prevent the accumulation of epoxy fumes. Avoid skin contact with the epoxy resin or hardener, as it may cause irritation. In case of skin contact, wash immediately with soap and water. If epoxy gets into the eyes, flush with water for at least 15 minutes and seek medical attention if irritation persists.

Keep the work area clear of other trades during and for 24 hours after installation to prevent contamination and ensure proper curing. Properly dispose of unused materials and clean tools according to manufacturer instructions. Follow all safety recommendations provided by Dur-A-Flex to ensure a safe and successful installation.

Necessary Tools and Equipment

To successfully install Dur-A-Quartz epoxy flooring, specific tools and equipment are required. A high-quality trowel is essential for applying the epoxy-quartz mixture evenly. Squeegees and rollers are used to spread and smooth the material, ensuring proper coverage and texture. A mixing drill with a paddle attachment is necessary for thoroughly mixing the epoxy resin and hardener. Sanding equipment, such as diamond grinders or sanders, is needed for surface preparation to achieve the required profile for optimal bonding.

Additional tools include a notched trowel for applying primer, a broadcast spreader for distributing quartz aggregate, and a vacuum or broom to remove excess aggregate. Safety equipment like gloves, goggles, and a dust mask are critical for protecting against chemical exposure and dust. Proper ventilation fans should be on hand to maintain airflow and prevent fume buildup. Moisture testing equipment, such as a Tramex meter, ensures the substrate is dry enough for installation. Buckets, mixing sticks, and application brushes are also essential for the process. Ensure all tools are in good condition to achieve a professional, long-lasting finish.

Common Mistakes to Avoid

When applying Dur-A-Quartz epoxy flooring, several common mistakes can compromise the quality and durability of the finish. One of the most critical errors is inadequate surface preparation, such as failing to properly clean or profile the substrate, which can lead to poor adhesion. Another mistake is not following the manufacturer’s mixing instructions, as incorrect ratios of epoxy resin to hardener can result in a weak or uneven cure. Ignoring moisture testing is also a frequent oversight, as excessive moisture can cause blistering or delamination. Additionally, applying the material in unsuitable environmental conditions, such as extreme temperatures or high humidity, can negatively impact the curing process. Broadcast quartz aggregate too heavily or unevenly can lead to a rough, uneven surface. Finally, not allowing adequate curing time between coats or before exposing the floor to traffic or chemicals can significantly reduce the system’s performance and lifespan. Avoiding these mistakes ensures a professional, long-lasting result; Proper training and adherence to instructions are essential for a successful installation.