Self-Leveling Slurry Systems

Introduction
Trafficote Systems incorporate epoxy resin with fine and powdered silica sand to produce a slurry that self-levels when applied at the proper thickness. While wet, additional sand can be broadcast into the slurry to provide a non-skid texture and increase thickness of the finished floor. These systems have a much higher resin content than a mortar, making them a good choice for wet environments or those applications with light to medium abuse and traffic. Self-leveling slurries require less effort and skill to install than a mortar system but provide far greater protection than a coating. Refer to the General Polymers Brand System Bulletins for the products required on your application. For each system you will find the components, coverage rates and typical batch quantities.

Inspection & Surface Preparation
Read General Polymers "Instructions for Surface Preparation" (form G-1) for complete details on preparing the concrete surface prior to installation. These systems are typically specified at 1/16" smooth or 1/8" non-skid. Because these systems self-level they will not hide surface irregularities, level an undulating substrate or hold thickness on a slope. Surface imperfections greater than 1/16" should be patched prior to installation of the Trafficote System. Trafficote Systems will not hold on a vertical surface. If cove base is required this should be done with a mortar material (TPM) prior to installation of Trafficote.

Every job should be inspected for certain conditions prior to installation. Check for adequate power, lighting, heat and ventilation. These systems should not be installed with a substrate temperature less than 50F. Best results are achieved between 65-80F.

Priming
Trafficote Systems are resin rich but a primer is still recommended. The primer will reduce concrete out-gassing, fill some surface profile and aid in leveling of the slurry. A high or 100% solids primer is preferred.

Aggregate Blend/Ratio
The aggregates used in Trafficote are a blend of 40-60 mesh silica sand and a fine powder (silica flour), sold separately. The specific amount for a typical batch is on the appropriate System Bulletin. It is best to premix the aggregates prior to addition to the resin. The coarser sand will keep the powder from clumping. If a scale is not available combine two parts, by volume, of the sand with one part of powder and mix.

Mixing
A 1/2" drill and paddle is all that is required to mix the resin and aggregate. The resin components should be combined and mixed first, then slowly add the aggregate blend and mix until uniform. Do not pump the paddle up and down as this can whip excess air into the mix. The specific amount of aggregate(s) added to a typical batch is detailed on the System Bulletin dependent upon the System chosen. If a scale is not available a workable mix uses equal parts, by volume, of resin and aggregate blend. Do not mix more material than can be placed and finished in 30 minutes.

Slurry Placement
The mixed slurry should be placed and spread on the floor immediately after mixing, pour the material in ribbons to aid placement. Material left in mass can result in a significant reduction of working time and leveling properties. A 1/4" v-notched trowel or squeegee, held at a 45 degree angle, is the right tool to spread the material and achieve the proper thickness. The slurry should level out the notches within seconds of placement. Check your thickness and adjust the angle or pressure used accordingly. Back roll the slurry with a loop or conventional roller to remove any trowel or squeegee marks. Back rollers will require spike shoes, as it will be necessary to walk in the wet material. If air is whipped in during mixing or placement bubbles may appear in the slurry within a few minutes of placement. Be prepared to back roll with a "spiny" or porcupine roller. This roller will not remove trowel marks but will break air bubbles.

Leveling properties can be impacted by temperature. In low temperatures a reduction in the amount aggregate will aid leveling but reduce coverage. In very warm temperatures additional aggregate can be added into the mix to insure thickness.

Broadcast & Grout (1/8" Non-Skid Option)
Allow the slurry to level for a few minutes after back rolling, but broadcast into the wet material within 30 minutes of placement. The broadcast aggregate supplied by Sherwin-Williams is a 40-60 mesh silica sand. Larger sand or aluminum oxide can be substituted. A larger aggregate size will increase texture but also consumes more resin for the grout and or topcoat. If done by hand, this step will also require the installer to walk in the wet, unbroadcasted material with spike shoes. The broadcast can be done with a hopper and blower or sand pot. The broadcast sand should be thrown or blown at an upward angle to allow the material to spread and fall gently into the wet material. Care should be taken not to walk in wet material, which has received the broadcast sand as it will not level back. The slurry is 60+ mils thick so a large amount of sand will be required, approximately 0.5 pounds per square foot. Broadcast until full saturation, no wet spots. Allow the material to cure fully prior to the grout or topcoat application, typically 8-12 hours.

A grout step is necessary to lock in the aggregate and reduce texture. If a heavy non-skid finish is desired a grout step may not be required. The broadcast layer significantly increases the thickness of the floor and will provide texture. If the additional thickness is desired but only a light non-skid texture, this can rarely be accomplished in one topcoat of material as the thickness of the material will trap too much air and pinholes will result.

Remove all loose sand prior to grouting. Spread the mixed grout material via squeegee or flat trowel and back roll. Use caution to not whip air into the material when mixing and while spreading. The rough sand texture traps a lot of air. Allow to cure overnight.

Seal Coat
Sherwin-Williams offers a variety of seal coat options; urethane, epoxy, gloss, satin, solvent-based, 100% solids, stipple or smooth finish. There are too many to discuss individually, refer to the Technical Data Sheet for the specified product. In general, the seal coat is applied with a roller at the specified coverage, and is back rolled. Prior to application of the seal coat, walk the floor and look for debris and other imperfections. To reduce texture the floor can be sanded prior to application.