How do I use the base coat?

It goes underneath the topcoat, just below the middle coat, to the right of the coat rack.

When using iCOAT over existing floors, is it better to fill medium/large voids with another material or should the iCOAT material be used?

We have a product for that purpose, it is called Patch and Fill. Large voids, in excess of 1/8″, will consume epoxy overlays to the point of impracticality. Unless you have a desire to keep a “rustic” look throughout your project, a patch or filler should be used.

I have heard that the iCOAT process can go over virtually any existing, sound surface? Is that really true? Are there limitations?

If the surfaces are similar in their expansion and contraction, and they are clean and prepped properly, you shouldn’t have any problems. Metal and fiberglass are different stories that require a much more thorough prep. Wood must be completely sealed from moisture by installing hydro-membrane and lathe.

Should iCOAT be used over interior flooring that is glued in place? (self-stick tiles, or vinyl flooring?)

Sure, but the quality of prep you put into your project yields a more durable final finish. If the tiles are over wood or upper flooring substrates such as OSB then it is not necessary to remove the tiles as they can be left as-is and sealed with a moisture barrier

Can iCOAT be used over existing hardwood, (aging foyer or revamp of entrance way, etc.). Should there be preparation (like adding a luan sub-floor).

Icoat can be used over plywood or OSB. Necessary prep steps involve rolling on a coat or two of hydromembrane then stapling stucco lathe with overlappedseams over the wood. Base mix is used to fill in the lathe and create a monolithic reinforced substrate.

What to do if there is residual adhesive on the existing floor?

Carpet and linoleum adhesives come off smooth concrete fairly easily. It is best to soften the glue with xylene or a stripper such as Jasco, then remove it with a wall shaver and 8” razor blade. If the concrete is heavily broomed and has glue then it may be necessary to grind the glue off. Black mastic should be cleaned as best as possible, rinsed to clean water then covered with a layer of undiluted Resin 221 which must dry before installation.

How much weight does the iCOAT process add to an interior floor (lbs/sq ft – assuming a “standard“ thickness of material)?

On average, about 1 lb per square foot.

What is the average thickness of an iCOAT installation?

1/16” to 5/32”. We have gauge rakes in our tool section that are used solely for the purpose of maintaining an even overlay depth.

iCOAT seems to be a multi-coat process. Is there any concern about delaminating?

No, our products are all compatible and bond, well above industry standard, to one another. The product can be applied over itself even if sealed with the use of Icoat Adhesion Enhancer.

How do you prep if the existing floor has been painted or epoxy coated?

Clean the floor, allow to dry, install a layer of Icoat Adhesion Enhancer with a pump can, allow to start to dry then rinse or mop the floor to clean water, install Icoat.

Is the iCOAT interior floor material the same as is used for exterior surfaces?

Yes with the exception of the recommended sealers. ICRU-6 is the preferred interior sealer and I-22/30 is best for outdoor application.

Will the iCOAT products seal a basement floor to potentially stop seepage of radon gas?

No, Icoat has joint filler compounds but makes no claims for Radon eradication. If you have radon gas contamination, it’s best to contact a local fire department for information about safe levels.

I believe iCOAT is essentially a concrete based product. As far as I know, there are only two kinds of concrete – 1) Concrete that has cracked, and 2) Concrete that is going to crack. Does iCOAT tend to follow that same trend?

Concrete should crack as planned by the contractor, however we know this isn’t true in all cases. Icoat has several methods and products for crack repair depending on the size of the crack. Icoat recommends Crack-RX100 for most cracks and hydromembrane over the Crack RX for interior floors. Many times it is beneficial to incorporate the cracks into the pattern or accentuate them as “decorative cracking” in a seamless stone pattern. If your concrete floor shows signs of buckling or dipping, and crack spread is greater than 1/4″, you may have root problems or a poor soil compaction beneath. Consultation with a professional is always suggested if there is any doubt.

When floors are surfaced done with iCOAT is the coating surface very slick? Does snow/rain make it even more slick?

Icoat overlay installations as taught by Icoat are all considered non-skid by ASTM slip tests. If the surface is troweled too smoothly then the surface may become more slippery however, Sherwin Williams sells a product called Shark Grip that can be added to the sealer to increase slip resistance.

Will iCOAT floors stain? Can they be cleaned with conventional floor cleaning materials?

iCoat recommends our fine barrier type sealers which are highly stain and chemical resistant. Most household cleaners can be used on Icoat flooring products but we have a whole line of cleaning products featuring Degrease for initial or heavy cleaning, Maintain which is a no-rinse floor cleaner which leaves the product looking freshly seale and Renew which is a high sheen buffable wax/ sacrificial coating that commercial clients desire.

How much working time is there with the iCOAT floor materials? Is the working time greatly affected by temperature and humidity (or lack thereof)?

Working time: Once the product is applied to the floor.
Open Time: Once the product is mixed and is still in the bucket.
Both working time and open time are greatly influenced by ambient temperature, material temperature and humidity. Concrete products lose their workability at 90 degrees so if the bags, water and Resin 221 are all 90 degrees or higher, then the material will not apply properly. We address hot weather application by NEVER diluting the Resin until a batch is ready to be mixed; this gives us the flexibility to use chilled or ice water for the mix. Ice water will extend open and working time significantly. Working time will additionally be affected by direct sunlight, substrate temperature and porosity and mix viscosity; installation of the adhesion enhancer according to instructions will prevent outgassing in porous floors and cool temperatures of hot substrates. Cooler weather conditions obviously have the opposite effect; open and working times are extended into undesirable gaps between application steps. Heated water, heaters to raise the ambient temperature and fans or blowers to move the air will all reduce working times.

What is the walk-on cure time typically? Is that affected by temperature and humidity?

As soon as the sealer dries completely the Icoat flooring can be opened to foot traffic, typically this is same day for the I-22/30 and the next day for ICRU or other dual component products.

When does the material reach its full strength?

Icoat flooring products reach a full cure at 28 days. This does mean that it’s safe to drop anvils and pianos prior to the complete cure.

Is the material somewhat flexible to tolerate potential movement due to expansion or contraction of the underlying surfaces?

The Icoat flooring product has exceptional tensile strength to tolerate movement expected with all acceptable substrates. The product will telegraph structural cracking from the substrate and is NOT designed to bridge cracks or expansion joints. Subsequently, there are epoxy solutions that are ASTM certified for concrete repair in DOT applications.

Does iCOAT actually adhere to most existing materials, or does it form a new – but somewhat separated – layer over the existing surface?

Icoat is bonded directly to the surface it is applied to with the exception of its application over wood. The hydromembrane provided the separation, the material is bonded directly to that and reinforced against delamination by the lathe.

Are there hazards when drilling or grinding the material after it sets? What is in the dust created? Fibers, etc?

Flooring (primarily concrete) products contain silica sand and proper respiration equipment should be utilized to avoid inhalation.

Does the product shrink or expand as it cures?

All concrete products are at their maximum volume when they are being installed. Because the Icoat flooring products are applied so thinly, there is insignificant evidence of shrinkage. Repairs or transition areas that require a thicker buildup of material should utilize Icoat Patch and Fill which is a rapid set product.

Is there any max (or min) temperature for proper installation?

Icoat recommends installation temperatures of 45 F and rising for installation of flooring products. Icoat products should not freeze before drying completely. There are no maximum temperatures as long as high heat installation techniques are employed. Warmer temperatures make the viscosity much easier to work with.

If a deep scratch penetrates the top sealer, is there concern about possible delamination because the next layer is exposed?

It is not likely that the epoxy could be scratched through completely but if it were then the answer would be determined by the substrate. If the core used was not water proof (i.e. – below the moisture barrier of wood) and became exposed to water then it would likely swell and cause delamination. The selection of Medex as a core will be insurance against many delamination causes.

Is the product permanently sealed (assuming no mechanical abrasion etc). Or, is there some form of sealer that should be used on a routine basis?

The epoxy is a permanent sealer for the countertop systems. It can be buffed from time to time to remove any scratching. The epoxy could be re-applied in the unlikely event that it was necessary.

Is a countertop four layers and a sealer? Are all the layers the same material (except maybe for color)?

Icoat requires only three layers as our product has significant advantages over similar product offerings; application is one brush coat, the edges and two trowel coats which are applied wet over damp. The countertop composite can be used for all layers. Countertop UF can be substituted for the final trowel layer for a smoother surface.

Is a countertop affected by common household cleaners and chemistry – bleach, counter top cleaners, dish soaps, SOS pads, disinfectants, etc?

Icoat counters are not susceptible to chemical damage from any household cleaners but abrasives should never be used as they can scratch the epoxy.

Is iCOAT weakened or attached by any known chemical?

Household chemicals do not affect Icoat countertops, there are many laboratory chemicals that could affect the finish; Icoat does offer a cyclo-aliphatic epoxy for extreme environments.

Will the material fracture and break like concrete?

Icoat counters are significantly more impact resistant than concrete, granite or corian countertops.

Can the edges of countertops be created to give an ogee or other decorative rounding effect?

Many edges can be replicated as desired however Icoat basic techniques seminars show two edges, flat and chiseled. These two looks are easy to do and replicate a high end granite product. Bull nose or rounded edges are indicative of low end granite or corian.

How much time will the average countertop take to dry? Time to reach ultimate durability and hardness?

Icoat recommends a week of cure time before normal use. The customer can use towels to protect the counter during curing.

Could an existing surface be too smooth to directly apply iCOAT – like a power-toweled garage floor or walkway?

Slick trowelled concrete can be etched with an acid solution to create an acceptable profile for resurfacing.

Is it possible to do exterior walls with iCOAT? Are there special considerations?

Yes, Icoat products work well vertically. Large jobs can be applied through a hopper gun or Graco texturemachine, then trowelled. Smaller jobs such as showers can be applied bu using a hawk or simply pouring the material on an upside down trowel as it is being applied.

How will salt and other road chemicals affect the iCOAT product during use?

Icoat sealer are resistant to salt and deicer damage. In places that could be affected maintain a good and current seal.

Is the product permanently sealed (assuming no mechanical abrasion etc). Or, is there some form of sealer that should be used on a routine basis?

Icoat recommends re-sealing every 2 to 5 years depending on the amount of wear, exposure and sealer initially selected.

Is the flooring surface material 2 coats/layers with a sealer?

Icoat flooring material can be applied with as few as one coat. There are occasions where multiple skim coats are required such as when filling in exposed aggregate, tile of other heavy profiles. The sealers should be applied according to product spec and desired gloss.

Is the coloring used resistant to sunlight fade, or aging?

Yes, all our colors are UV stable and also the sealers all contain UV additives.

Is the exterior material subject to mold and discoloration like normal concrete?

All Icoat products are sealed with a barrier forming sealer that prevents staining, oils and rust can stain the product if left on too long. Icoat sealers are also chemically resistant to most household products.
Icoat products comprise the finest particulate acrylics available and are 100 percent non-reemulsifiable by water. Areas with extreme hydrostatic pressure such as pool walls should not be coated with Icoat products.

Does chlorine or other potential pool chemistry affect iCOAT?

Chlorine and acid can fade Icoat products in heavily concentrated form and salt damage can occur to substrates in salt water pools.

Is iCOAT affected by common household or garage materials (motor oil, bug sprays, antifreeze, harsh floor cleaners, weed killers, brake cleaner, WD-40, etc.)?

Brake cleaner can soften sealer and motor oils can cause staining if left on the surface for an extended period however most other household products will have no affect on the properly sealed Icoat surface.

Can a heavy duty power washer be used on iCOAT? Are there any risks?

Powerwashers work very well to clean Icoat products. Use no more than 4000 psi and no less than a 25 degree fan tip.

There seem to be a few product offerings for epoxy type garage floor sealers. Can part of the iCOAT process be used to seal and beautify a sound existing garage floor? If so, can it be colored – like the other folks have done? Or, are we better off leaving that particular market to the “other folks”.

We have a full line of garage systems under the Ipoxy label. Used in conjunction with the Adhesion Enhancer and the ICRU6 our garage floor system is not only aesthetically pleasing but is designed to withstand even the harshest of environments.

Does the color of an external iCOAT installation go through the product or is it a surface colorant?

Many of the colors penetrate the surface when applied topically. Icoat Dispersing Colors can be mixed integrally as well.

During installation how much affect will weather have? Is there a period after a rain that the iCOAT cannot be applied? If the surface is cool or cold, can iCOAT be applied? If there is a threat of rain within 12 hours, can iCOAT be applied? Will rain affect the individual layers of iCOAT as they are being applied?

Icoat needs to be applied to a nearly dry and clean substrate. After rain it is a good idea to clean any possible contaminants from the surface before resurfacing. Icoat products can get wet once they have been allowed to dry completely, if it rains between coats it is also advisable to rinse the entire job to remove contaminants and ensure color uniformity. Icoat products should be applied in temperatures of 45 F and rising and should never be allowed to freeze before dry.