General Advice for Repairing Floors with FS or Rust-Oleum Mathys Repair Products

It is essential to read the relevant data sheets and follow the instructions. We also recommend you read the following before proceeding with repairing your floor. If you require assistance please don't hesitate to contact us.

Preparation Advice

General Notes: It is essential that all areas to be repaired are thoroughly clean and do not have any flaking paint prior to repairing.

It is essential to read and follow the instructions in the relevant data sheet.

Joint Repairs

1. Joint Material Replacement Only

Clean out the existing joint. Use masking tape at the edge of the joint to ensure a neat repair. For deep joints it may be necessary to put in a backer rod to prevent the material from seeping away or from using too much product. Mix and apply either FS Epoxy Joint or FS Poly Joint (NB: FS Poly Joint needs priming with FS Epoxy Primer first) and pour into joint – see data sheet for instructions. Note that FS Poly Joint is more flexible than FS Epoxy Joint and should therefore be used if there is known movement of the concrete slabs. You could also consider Rust-Oleum 5160 Flexi-Joint Filler.

2. Arrisses of Joint Broken Down

Where the arrisses of the joint have broken down it is necessary to remove any joint filler and clean out the joint thoroughly. The edges of the concrete should be straightened up using a bolster, angle grinder, or similar, so that there is a minimum of 3mm of vertical depth at the edge. (You can apply FS Epoxy Patch to a tapered edge but this will create a weak point that is likely to fail at some time.) Having cleaned up the area this should be primed using a small amount of the resin for the FS Epoxy Patch, or use FS Epoxy Primer for larger areas. Ensure that the resin is mixed adequately or it will not cure – see data sheet for instructions. Once cured a saw cut should be made, following the line of the original expansion joint and to the same width if possible, through the repair. This should be 15mm, or more, deep. The new joint should be filled with either FS Epoxy Joint or FS Poly Joint - see data sheet for instructions. Note that FS Poly Joint is more flexible than FS Epoxy Joint and should therefore be used if there is known movement of the concrete slabs. You could also consider Rust-Oleum 5160Flexi-Joint Filler.

Floor Repairs

Two or three pack epoxies are generally the strongest and durable solutions and should be considered if the budget will allow.

Holes

Where there are holes in the concrete slab the edges of the concrete should be straightened up using a bolster, angle grinder, or similar, so that there is a minimum of 3mm of vertical depth at the edge. (You can apply FS Epoxy Patch or FS Epoxy Patch Fast Cure to a tapered edge but this will create a weak point that is likely to fail at some time.) Having cleaned up the area this should be primed using a small amount of the resin for the FS Epoxy Patch, or use FS Epoxy Primer for larger areas. Ensure that the resin is mixed adequately or it will not cure – see data sheet for instructions. Rust-Oleum also have two epoxy mortars which could be considered. These are 5180 Epoxy Repair Mortar and 5190 Epoxy Repair Mortar Deep Fill (for deeper repairs). Rust-Oleum also manufacture 5110 Verti-Patch for walls, 5140 Light-weight Rpoxy Tepair Mortar and 5412 Epoxy Repair Putty for small repairs.

Rust-Oleum Pegacrete is a cementitious repair materail and is easy to apply - just add water.

Rough Concrete, where aggregate exposed or similar

Smaller areas should be treated in a similar way to in 'Holes' above. You should ensure that a minimum of 3mm (often more) depth of product covers the whole area.

Rust-Oleum 5150 Speed Patch (cementitious product) can be used for areas of several square metres of a poor concrete floor. For large areas Rust-Oleum Basecoat Rapid SL can be used. This is also a cementicious product that is mixed with water. For very large areas it is recommended to use a specialist contractor. We have approved applicators who can install these systems and could actually save you money.

You may also wish to consider using FS Epoxy Screed or FS Polyurethane Screed which are more durable than any cement based systems. (For food production areas we would recommend FS Polyurethane Screed.) Note: FS Epoxy Screed or FS Polyurethane Screed are not shown on our website as these are for specialist contractor application only. Contact us for details or for a quotation.

Weak Sand and Cement Screeds

For weak screeds FS Epoxy Binder can be used to increase the strength of the floor. Providing the screed is not contaminated it is generally in order to sweep thoroughly to remove dirt. For contaminated screeds any contamination should be removed and, if necessary, the screed should be repaired prior to applying the FS Epoxy Binder. FS Epoxy Binder cannot be used on previously coated screeds. See data sheet for instructions.

Application of 2 or 3 Pack Repair Products

Additional notes to assist with a successful application of 2 or 3 component products: When products are delivered store them indoors, ideally at a temperature of 15 to 25C as this temperature range is the best for application purposes. It is essential that the area to be repaired is completely dry, and any water or oil leaks are sorted prior to application. Organise the product and mixing station. You will require the following:

  • Plastic sheeting or cardboard to mix on
  • A slow speed drill and mixing paddle
  • A steel trowel
  • Rubber gloves
  • Safety glasses for the person mixing
  • Solvent or white spirit for cleaning up spills and for cleaning the trowel

Use a slow speed drill and paddle to mix the resin materials. The resins should be mixed until a homogeneous solution is obtained. A trowel can be used to mix the (previously mixed) resin with the aggregate.

NB: Inadequate mixing will mean that the product will not cure.

Once mixed the product should be applied to the floor as quickly as possible as there is a short usable time or 'pot life' – this time will be less the higher the temperature of both the product and the work area. (Data sheets give an indication of the pot life at 20C.) This is quite a resinous product (which makes it stronger) and a better finish will be achieved if the trowel is kept clean by wiping with solvent (we can supply FS Tool Cleaning Solvent if required) during the application of the mortar.

Ideally repairs should be sealed with an epoxy coating system such as the FS Epoxy Coating range or FS Epoxy Sealer. Cementitious products should generally be left for a few days before being coated. Refer to the individual product sheets for specific advice.

Disposal of Containers and Unused Product

Please ensure that containers are empty, and that if there is any unused product that you need to dispose of, that this is mixed to render it inert prior to disposal.

The above notes are for guidance only and First Solution Supplies cannot guarantee a project's success due to situations beyond their control.

Should you require an experienced contractor to apply a coating system, including fibreglass reinforced systems we can arrange this.

We can also supply floor, wall, metal coatings and roofing products and services.

First Solution Online

10 Bailey Lane, Wilton, Salisbury, Wiltshire, SP2 0FS

Tel: 01380 831299 Email: tech@firstsolutiononline.co.uk Web: www.firstsolutiononline.co.uk