WO2000001903A1

WO2000001903A1 - Self-smoothing decorative resin flooring system

Info

Publication number: WO2000001903A1
Application number: PCT/AU1999/000542
Authority: WO
Inventors: Graham Kevin Brown
Original assignee: Amtred Limited
Priority date: 1998-07-03
Filing date: 1999-07-02
Publication date: 2000-01-13
Also published as: AUPP446798A0

Abstract

A method for covering a substrate, such as a concrete or masonry floor with a seamless self-smoothing surface covering comprising the application of a base coat of a first self-smoothing settable material to the substrate, allowing the base coat to partially set or cure, and then applying one or more subsequent coats of contrasting settable materials and allowing the composite surface to set or cure. The resultant surface coated substrates are also claimed.

Description

SELF-SMOOTHING DECORATIVE RESIN FLOORING SYSTEM

TECHNICAL FIELD

The present invention relates to a self-smoothing, decorative resin flooring system for continuous or seamless flooring, or the like. The invention has particular application to commercial or industrial environments wherein a readily cleanable or serviceable surface is an essential requirement, but is not limited thereto. For example, it is adaptable for use in domestic environments.

The present invention also relates to an innovative method of producing such surface finishes to provide a decorative and practical finish to such surfaces.

BACKGROUND ART The industrial, commercial, and to a lesser extent, domestic flooring markets, have long been catered for by a vast range of seamless floor coating systems. Such flooring systems are specified for use in many industries, including manufacturing, food processing, transport, health, entertainment (e.g. clubs and hotels), to name a few.

These systems can be categorised into three basic sections. Coatings, self-smoothing screeds and mortars. They can be based on a number of binders, including epoxy, polyurethane, polyester and methyl methacrylate. Some of these systems are of a decorative nature, such as coloured flake floors, epoxy and polyurethane based terrazzo, and coloured aggregate screeds. All of these systems are highly labour intensive and often expensive and restrictive in appearance and design.

Many of the known systems have proved to be very effective and long lasting. However, they do not appeal aesthetically. The variation in appearance of the prior art finishes is at present restricted to colour and texture, and it is an object of the present invention to provide a variety of decorative options for various flooring or other surface finishing for commercial, domestic and industrial applications whilst maintaining the seamless, slip resistant and hard wearing qualities of existing systems.

DISCLOSURE OF THE INVENTION It is an object of this invention to provide a surface finishing system which goes at least some way towards overcoming or at least minimising the prior art problems or limitations outlined above, and for providing a clear alternative choice for use of builders and consumers.

It is a further object of this invention to provide an improved surface finishing system which is universally adaptable to various flooring applications, or to other similar surface applications.

It is another object of this invention to provide a surface finishing system which is relatively simple and cost effective in its application.

These and other objects of this invention will become more apparent from the following description.

According to one of its aspects, the present invention provides a surface finishing system comprising a settable seamless and substantially impervious surface including optional patterned, decorative or ornamental surface finishes. The present invention includes the methods of forming or producing the new surface finishing system and the floors or other surfaces when obtained by the inventive methods.

According to a preferred aspect of the invention, a base coat of a first self- smoothing settable material, such as a polymeric (e.g. epoxy) material is laid to a thickness of about 1.5-2.5 mm (but not restricted thereto) on a suitable substrate, e.g. concrete, following appropriate preparation of the substrate. Prior to the base coat setting, i.e. whilst it is still in a plastic state, a spatter coat of a second settable material (e.g. an epoxy composition) is sprayed over the previously applied base coat, and allowed to set. The epoxies above are used as an example only, as polyurethanes and other suitable resinous systems can be used. By combining base coats of suitable viscosity and surface tension properties and colour with similar and sometimes incompatible properties of the topcoat, e.g. in a contrasting colour, a marble or terrazzo effect is produced.

The combinations described above can produce both high profile and low profile (slip resistant) finishes. By varying the colour (or colours in multi topcoat applications) an infinite variety of patterns or finishes can be achieved. Adjustment of both pressure and orifice in the spray equipment will alter the pattern and texture to suit requirements.

A further embodiment of the invention is the incorporation of lightweight aggregate in the topcoat which float to the surface leaving an effective low-slip finish for both dry and wet application areas.

The invention combines the practical considerations as to cost and down times of self- smoothing flooring with the aesthetic appeal of epoxy-based marble or terrazzo. This system requires the applicator to lay a base coat of a specified colour of self-smoothing flooring, and subsequently spray a further coat (or coats) of another colour to achieve a marble or terrazzo (or other decorative finish) appearance. The floor is then polished, if required, as per traditional self-smoothing or vinyl flooring. The range of decorative effects are achieved by varying the viscosities of the materials used, the size of the orifice in the spray gun and the pressure at which it is applied.

BEST MODE OF CARRYING OUT THE INVENTION The invention will now be described by way of example only with reference to the following non-limiting examples thereof.

According to a first embodiment of the invention, a previously layed concrete/cementitious floor acts as a base or as a substrate for the inventive flooring system. Mechanical scarifying, vacuum blasting, or hot compressed air techniques can be used to prepare the substrate surface. The substrate is primed by roller coating or spraying a film of epoxy mixture onto the concrete. With porous substrates, two coats of primer will normally be required.

When the primer layer has dried, a first layer of a self-smoothing material is applied by pouring onto the prepared, primed substrate. For example, for a smooth epoxy floor, an appropriately coloured, three component amine-cured epoxy material (e.g. supplied by Amtred) is applied as a semi-free flowing liquid to a nominal thickness of about 2.5 mm over the floor area to be coated, using a straight edged trowel. After application, the coated surface is thoroughly de-aerated by using a multiple-spiked roller for up to about 10-15 minutes after application. Use of spiked shoes by the applicator personnel is also recommended, paying particular attention to edge and joint detail. For timber substrates, a flexible base coat is preferred .

Prior to the base coat setting (usually within 20 minutes), and with the surrounding wall surfaces suitably masked to avoid contamination by the top coat material, the top coat material is applied as one or more layers to the previously layed base coat using a hopper gun and minimum 12 cfm compressor, with the orifice of the gun at 6 mm, and with the pressure set via the regulator to approximately 30 psi for high profile finish and to about 50 psi for low profile finish, at an ambient temperature of 20 °C. Viscosity and pressure change with different ambient temperatures.

The top-coat is preferably a three-component water-based, self-smoothing epoxy material for the low-profile finish, and a polyurethane or other polymeric material for the high-profile finish. Alternative finishes, by way of example, may incorporate anti-slip aggregates, sprinkled on flakes, and other special aggregates.

When the top-coat has cured (usually within 24 hours for light traffic), the surface can be sealed with a water-based polyurethane sealer (e.g. as for vinyl floors), if required.

The application process is both simple and efficient with a four man team completing in excess of 300 square metres in a day. This is a considerable saving on existing systems that often need subsequent grinding, sealers etc. For instance, an epoxy based terrazzo system, which is similar in appearance and of similar size, will take at least four days to complete with as many men.

Typically, a flooring system according to the present invention, according to the above non- limiting embodiment, may have the following features and properties:-

Seamless, dense surface - easily cleaned and hygienic. Fully sealed, compacted - excellent chemical resistance. - Abrasion and impact resistant - long maintenance-free life.

Slip resistant or non-slip embodiments. Wide range of colours and surface finishes. Fast application - minimum down-time and cost effective application.

The flooring system of the present invention is ideal as an alternative to, or replacement of, the following flooring systems, but is by no means limited thereto.

(i) Terrazzo in an epoxy matrix. This system requires the applicator to lay say 20 mm of a mixture of coloured aggregate and epoxy resin and then grind the floor several times to achieve a smooth finish which is then polished similar to traditional terrazzo producing an impervious finish suitable for a range of dry area industrial applications. This system is very expensive and highly labour intensive. Shut down times are lengthy .

(ii) Self-smoothing epoxy flooring. This system requires the applicator to lay say 3-4 mm of a specialised mix of epoxy, silica, sand and additives which finds its own level. It is then polished, "s say vinyl is, producing an impervious finish suitable for a range of dry area industrial applications. It is considerably cheaper than the above but suffers from a rather plain appearance. Although an exemplary embodiment of the present invention has been shown and described, it will be apparent to those having ordinary skill in the art that a number of changes, modifications or alterations to the invention described herein may be made, none of which depart from the spirit of the present invention. All such changes, modifications and alterations should therefore be seen as being within the scope of the present invention.

It should be appreciated that the present invention provides a substantial advance in self- smoothing flooring systems, providing all of the herein-described advantages without incurring any relative disadvantages.

Claims

CLAIMS:

1. A method for covering a substrate with a seamless self-smoothing surface covering consisting essentially of the steps of applying a base coat of a first self-smoothing settable material to the substrate, allowing said base coat to partially set or cure, and whilst still in a plastic state applying to said base coat a coating of a second settable material either at random or according to a predetermined pattern, and allowing the resulting composite surface to set or cure.

2. The method of claim 1 , wherein the base coat and the second coat are of contrasting colours.

3. The method of claim 1 or claim 2, wherein the second coat is applied as a random spatter coat to the base coat.

4. The method of any one of the preceding claims, wherein the base coat and the second coat are applied by spraying.

5. The method of any one of the preceding claims, wherein the substrate is concrete, masonry or hardboard.

6. The method of any one of the preceding claims, wherein the base coat and the second coat are selected from self-smoothing settable resinous materials.

7. The method of claim 6, wherein the properties of the base coat and second coat materials are selected as to, but not limited to, colour, viscosity and surface tension such that a resultant marble-like or terazzo effect is produced.

8. The method of claim 6 or claim 7, wherein the base coat and the second coat are applied by spraying through variable sized apertures or orifices, and at variable pressures to produce different textured surface finishes, including high profile and low profile surfaces.

9. The method of any one of the preceding claims wherein the second coat includes aggregate material.

10. A method according to claim 1, wherein one or more additional coatings of settable materials are applied to the composite surface.

11. A method according to claim 10, wherein a clear coating is applied as a top coat to seal and protect the underlying composite surface.

12. A method according to any one of the preceding claims wherein the base coat and the second and subsequent coats are selected from resinous coating materials including epoxy resins.

13. A method according to claim 11, wherein the top coat is selected from the group consisting of acrylics, epoxides, urethanes and polyurethanes.

14. A method according to any one of the preceding claims, wherein the substrate is prepared for surface coating by one or more of mechanical scarifying, vacuum blasting, hot compressed air techniques or acid etching, and the substrate is primed by the application of one or more coats of epoxy coating material.

15. A method according to any one of claims 1 to 3, 5 to 7 or 9 to 14, wherein the base coat is applied by pouring on to the substrate as a semi-free flowing liquid and spread over the substrate by any suitable means.

16. As a new article of manufacture, the surface coated substrate produced by the method of any one of the preceding claims.