DURABAK™ Safety Coatings

APPLICATION TIPS

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Surface Preparation General Directions Dos and Don'ts Surface Preparation For Specific Adhesion Concrete Concrete plus primer Asphalt Aluminum Metal Wood Paint and Varnish Rubber Fiberglass Ceramic Tile Epoxy Surfaces How To Apply Roller Application Brush Application Important Advice! Coverage Spray Application Important Advice! Repairing Durabak	The Care and Maintenance of DURABAK™ Surfaces General Care and Maintenance Alternative Methods Rotary Machine Rinse-free detergent Automatic Scrubbers Specific Cleaning Problems Grease Spillage Removal of sticky substances Removal of organic stains Accelerator Silicon Carbide METCOTE™ DURAGLOW™ DURAZZO™ SAFTI-TRAX™
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SURFACE PREPARATION

NOTE: Surface preparation and application instructions for both DURABAK™ and DURABAK 18™ is identical unless otherwise noted.

IMPORTANT – READ CAREFULLY!
DURABAK™ will bond well to properly prepared, clean, thoroughly dry surfaces. On sound-painted surfaces, paint must be fully dried or cured to manufacturer’s specifications. The solvents in DURABAK™ will not soften or attack properly dried or cured paint. For fully-cured two-part epoxy substrates, contact COTE-L Industries or your DURABAK™ distributor before application. (First, see Paint and Varnish #5)

GENERAL DIRECTIONS

Always thoroughly clean the surface of all oily or waxy contaminants and use recommended cleaning solvent. Leave no residue. Always do a small test on the substrate to ensure adhesion.

NOTE: Due to the possibility of slight batch color variations, mix partially used cans of DURABAK™ with new cans as they are opened during applications.

DO’S AND DON’T’S

SURFACE PREPARATION FOR SPECIAL ADHESION

IMPORTANT – READ CAREFULLY!
The following information is provided as a guide only, because substrates can differ significantly. All surfaces should first be tested to ensure adhesion. Contact COTE-L Industries for test design.

CONCRETE
For best results, NEW concrete should:

• Be fully cured, for at least 28 days.
• Have a brush finish.
• Be hand troweled (if already power troweled, test for adhesion of DURABAK™).
• Be thoroughly cleaned with a citric cleaner or equivalent, rinsed with water, and thoroughly dried.
• Be wiped with Xylene and allowed to dry, until solvent has evaporated, immediately before applying DURABAK™. (This is recommended, for best results, to ensure there is no remaining residue on the surface.)

NOTE:

• If the new concrete contains plasticizers, a small test for adhesion is essential. A primer may be needed if there is poor adhesion.
• If the concrete is oil-soaked, refer to instructions for oil-soaked concrete (see below).

OLD concrete should:

• Be completely dry before application of DURABAK™.
• Be shotblasted, if possible, and rinsed with water.

or

• Be abraded with a scarifying machine (leaving a roughened surface) and brushed off.

or

• Be thoroughly cleaned with muriatic acid wash.
1. Use 45% to 50% muriatic acid solution mixed with 3 to 4 parts water.
2. Agitate solution on surface with a hard-bristled deck brush for approximately 10 minutes, to open pores on surface.
3. Rinse off with a 5% ammonia/water solution to neutralize acid. (Failing to neutralize acid could leave residue which might cause delamination.)
• Be dried completely. If necessary, use a heat source.
• Be brushed off to remove all residue.
• Be wiped well with Xylene immediately before applying DURABAK™. Let the Xylene evaporate before applying DURABAK™.

NOTE:

• If the old concrete contains plasticizers, a small test for adhesion is essential. A primer may be needed if there is poor adhesion.

OIL-SOAKED CONCRETE

1. Open pores of concrete with muriatic acid and rinse, as above.
2. Apply an oil emulsifier and agitate with deck brush for 10 minutes.
3. Rinse with hot water.
4. Rinse twice with cold water.
5. Dry completely.
6. Wipe with Xylene immediately, and then let the solvent evaporate before applying DURABAK™.

NOTE: For chemically-soaked concrete, or other unusually difficult surfaces, contact COTE-L Industries.

SEALED CONCRETE

Sealed concrete should first be tested for DURABAK™ adhesion:

1. Clean surface thoroughly.
2. Roughen surface.
3. Brush surface off thoroughly.
4. Rinse with water and dry thoroughly.
5. A Xylene wipe is recommended. Let solvent evaporate.
6. Apply DURABAK™.
7. If delamination occurs, sealer must be removed by mechanical means (i.e., shot blasting or scarifying).

While it is not usually needed on concrete, a primer can provide enhanced adhesion. Contact COTE-L Industries for specific information on surfaces to be primed.

CONCRETE PLUS PRIMER

DURABAK™ exhibits good adhesion to new acrylic and polyurethane primers applied and overcoated to manufacturers recommendations. Check to make sure primer is compatible with one-part moisture-cured polyurethanes. Be sure to apply DURABAK™ within time specifications of primer manufacturer. Aim for the first third of the recommended window of opportunity for overcoating.

ASPHALT

1. Prime surface with a mineral spirit or water-based driveway sealer according to manufacturer’s specifications. Be sure the sealer is compatible with both asphalt and one-part moisture cured polyurethanes.
2. Apply DURABAK™ when primer is thoroughly dry.
3. For oily asphalt, contact COTE-L for proper cross-link primer.

ALUMINUM

1. Abrade to obtain rough surface. May or may not require additional primer. Recommend test for adhesion.
2. If a primer is needed, use an etch primer for aluminum which is compatible with moisture-cured polyurethanes. Apply during the first third of the recommended overcoat window, after the primer is touch dry.

METAL

All smooth metal should be thoroughly cleaned, aggressively roughened and primeds with an etch primer which is compatible with moisture-cured polyurethanes. DURABAK™ adheres well to cured painted metal. Most rough metal surfaces such as pitted rust need not be primed; however, all loose scale should be removed. COTE-L recommends that a small area be pre-tested with and without primer. On applications of extreme wear, such as step nosings, a primer is highly recommended.

CAUTION! When priming metal surfaces, the primer must be fully dry before overcoating. Careful attention must be given to manufacturer’s recommended window of minimum and maximum time for overcoating primer with polyurethanes. When using primers, a small test must be done to ensure adhesion of primer to DURABAK™. Aim for the first third of the recommended window of opportunity for overcoating.

WOOD

If wood texture is rough, it may not require special preparation. For best results, abrade surface of wood with 40-grit sandpaper before applying DURABAK™. Some pressure-treated woods may need priming. If in doubt, make a small test application first. DURABAK™ will bond to wolmanized treated wood without priming.

NOTE: Wait 4 hours after primer is touch dry before overcoating with DURABAK™.

PAINT AND VARNISH

1. Remove all peeling, cracking or chipping paint.
2. Clean surface thoroughly.
3. For best results, lightly abrade surface with an 80-grit sandpaper.
4. Clean the surface with a good cleaner, such as tri-sodium phosphate (TSP). Test in small area to make sure cleaner isn’t softening the painted surface.
5. It is strongly recommended to wipe surface with Xylene before applying DURABAK™.
6. In the case of epoxy coatings which become very hard with age, clean, then abrade surface with 40-grit sandpaper. Rinse, dry, and test for adhesion. If poor adhesion occurs, soak with Xylene for 10 minutes, wipe off, roughen, and wipe once more with Xylene.

For more information, contact COTE-L Industries.

RUBBER

Clean well using detergent or cleaning solvent, such as rubbing alcohol, to remove all surface release agents. Rinse well and allow to dry. Abrade surface aggressively, wipe off with Xylene, and then apply DURABAK™.

NOTE: DURABAK™ will not bond to chlorinated rubber.

FIBERGLASS

Good adhesion can be obtained on unweathered gel-coated glass, rough fiber, side molded glass, and smooth-mold resin-side glass. Surface should be free of release agents, waxes and other production additives, then roughened well with 40-grit sandpaper to remove all gloss, leaving a high profile surface. To ensure optimal bonding, use COTE-L's METCOTE™ primer, or an epoxy primer compatible with both fiberglass and moisture-cured polyurethanes. Do a small test for adhesion.

CERAMIC TILE

Remove glaze from tile with a grinder, rinse with water, and let dry. Apply an epoxy primer compatible with ceramic tile and moisture-cured polyurethanes, and let dry thoroughly. Then apply DURABAK™ within 12 hours.

EPOXY SURFACES

To apply Durabak to old epoxy surface, do a small test for adhesion:
 
 a. clean surface, rinse with water, and let dry
 b. roughen surface with 40-grit sandpaper
 c. wipe with xylene on a rag to remove any residue left from cleaning
 d. apply 1st coat of Durabak and let dry
 e. apply 2nd coat of Durabak and let dry for 2 days
 f. take a screwdriver and try to peel the Durabak off the surface
 g. if it comes up in small pieces, you have a good bond
 h. if it comes up in sheets, you need to re-prime according to manufacturer’s instructions

HOW TO APPLY

DURABAK™ for roller, brush or spray applications, is available in one-quart and one-gallon containers. For volume applications, it is also available in five-gallon containers by special order.

Before applying DURABAK™, it is important that the surface to be coated is completely clean and dry. (See Surface Preparation.) Mask all areas not to be coated. Remove masking tape as soon as possible after application of second coat, using a razor knife to cut along the taped edge.

IMPORTANT – READ CAREFULLY!

DURABAK™ contains flammable solvents. Ensure proper ventilation and fire precautions.

ROLLER APPLICATION

Apply DURABAK™ with special, open-foam stipple roller (only available through COTE-L Industries, or an authorized DURABAK™ dealer). Use only a DURABAK™ special stipple roller, which is designed to evenly distribute the embedded rubber granules on application – other rollers will cause clumping of the rubber granules. Roller sleeves are available in 9” and 4” sized. One 9” roller sleeve is good for approximately 1 to 1½ gallons.

Apply first coat of DURABAK™ as a thin coat to fully cover. When touch dry – usually within 1½ to 3 hours – apply second coat. To avoid “mud cracking” or pooling, do not apply DURABAK™ thickly. Between coats, pour a small amount of Xylene over rollers, so rollers will not dry out. Intercoat / curing time may be significantly shortened by the use of the special accelerator (see section on accelerator). Extreme climactic conditions of heat, humidity and cold can shorten or lengthen this period.

NOTE: DURABAK™ clear must be applied in thin coats to avoid bubbling.

BRUSH APPLICATION

DURABAK™ can be applied with a soft paint brush, in two coats at right angles to one another. (DURABAK™ is not a paint, and should be laid onto the surface, in one direction, not brushed out as an oil or latex paint.) Between coats, clean brush well with Xylene, only. The second coat can be applied as soon as the first coat is touch dry (usually within 1½ to 3 hours). Extreme climactic conditions of heat, humidity and cold can shorten or lengthen this period.

COVERAGE

One quart covers a flat area of about 15 square feet in two coats; one gallon covers approximately 60 square feet with two coats, with a final dry coat thickness of approximately 25 mils.

IMPORTANT ADVICE!

• DURABAK™ should be stirred thoroughly before applying – preferably with an electric paint mixer attachment – as shaking can will not distribute rubber granules evenly.
• Stir periodically to maintain rubber granules in suspension.
• To avoid “mud cracking” or loss of slip-resistance, do not allow DURABAK™ to pool.
• DURABAK™ is a moisture-cured product. An open or partially used can will thicken and eventually become unusable. Seal can well and turn upside down for a few seconds. This will seal any space in the can and may prolong the life of the unused portion of DURABAK™. Putting unused portion into a smaller container may help prolong the life of the product, as well. Make sure that the rim of the new container remains free of DURABAK™ to avoid difficulty in reopening the container.
• If the product thickens slightly, it can be thinned by using up to 15% Xylene without affecting performance.

IMPORTANT:

• Other solvents can cause product failure. Do not dilute product or clean rollers, brushes or spray guns with lacquer or alcohol-based thinners.
• Once the consistency of the product has become pasty and unmixable, it should be discarded. If DURABAK™ is thick, but still liquid, it can be thinned with Xylene and used.
• Normally, DURABAK™ can be subjected to light foot traffic within 6 to 12 hours of application. It takes approximately 4 days to fully cure: less in hot humid conditions, and more in cold dry weather. The coating should not be subjected to cleaning or chemical exposure until fully cured. For specific extreme kinds of loading, consult your DURABAK™ dealer.
• An accelerator can be used to decrease drying time under the following conditions:

¹Do not use an accelerator with DURABAK 18™ in hot/humid weather. It may increase drying time.
²Please check with COTE-L before using accelerator with DURABAK 18™.

• With DURABAK™ (but not with DURABAK 18™) an accelerator can be used in dry, cold temperatures, the dry/cure time of DURABAK™ can be reduced significantly by using COTE-L’s accelerator. In hot, humid weather, an accelerator is not necessary. In the case of DURABAK 18™, an accelerator will not work to decrease the drying time.
• PLEASE NOTE that full curing time only affects the amount of time required to wait before subjecting the surface to cleaning and chemical exposure. Surface can be subjected to loading and light foot traffic long before this minimum time requirement.

SPRAY APPLICATION

DURABAK™ can be sprayed using a simple shutz gun, a hopper gun, or professional spray equipment. Make sure to thoroughly mix DURABAK™. A drill with a mixing adaptor works best. DURABAK™ should flow through the spraygun easily and can be thinned with Xylene.

1. COTE-L’s shutz gun with a ¼” orifice (and no filter), attached to a 45-60 psi compressor.
• Attach spray gun to compressor air line, giving pressure of 40 to 60 psi.
2. Use a conventional spray gun, such as Binks #2001, with the following specifications, or equivalent: 67 fluid nozzle; 567 fluid needle; 67 PB air cap; heavy-duty (#54-1372) needle spring; 2-28 teflon fluid packing; ½” I.D. (#71-283) fluid hose with 3/8” connectors (#72-1333), and 3/8” I.D. air line with ¼” connectors (#71-1355).
• To remove contaminants from the air line, use Oil & Water extractors mounted at the pressure tank.
3. Sears Craftsman No. 15524 (or De Vilbiss AS 300) with external mix nozzle. Requires 7 CFM. Use compressor with 9 CFM at 50 psi. (For more information, call De Vilbiss Air Power Tools at (901) 423-7983.)
4. Airless spraygun: Graco Bulldog 33:1 with air intake pressure = 6-7 bar (90-100 psi). Outlet pressure = 100 bar (+/- 3000 psi). Tip: 0.039 ins (ie 35-39 thou). Delivery rate: 2.9 gallons per minute.
5. For smooth DURABAK™, Graco Bulldog 33:1 with 21-23 thou. tip.
• Use a respirator with chemical absorbing cartridges, such as Binks #40-128.
• Before starting the job, spray a few short bursts away from the surface to test that everything is working properly.
• If DURABAK™ does not spray easily and evenly, thin with Xylene.
• Spray an even coat over the entire surface to be covered. Be careful not to apply coat too thickly.
• When surface becomes tacky – between 30 minutes and a few hours, depending on weather conditions – spray second coat. Extreme climactic conditions of heat, humidity and cold can shorten or lengthen this period.
• Intercoat / curing time can be significantly shortened by use of special accelerator (see section on accelerator).

IMPORTANT ADVICE!

• Spraygun manufacturers often change model numbers. Consult individual manufacturers for superceded models.
• Remove any over-spray immediately with Xylene. Once cured, DURABAK™ is very difficult to remove.
• Solvents released when spraying are flammable. Observe all fire precautions. Proper ventilation is required.
• Clean spray gun between coats and immediately after job is completed. Use only Xylene.

THE CARE AND MAINTENANCE
OF DURABAK™ SURFACES

Once DURABAK™ coatings have fully cured, they are very easy to maintain. Because DURABAK™ cures to an impermeable membrane, all dirt sits on the surface.

CAUTION! If dirt sets in on DURABAK™ surface while it is soft and before it is cured, it could become permanently imbedded.

1. Use any general non-chlorinated floor cleaner, from a neutral household cleaner to a degreaser.

NOTE: DO NOT USE ANY CHLORINATED CLEANERS.

1. IMPORTANT! For best results, use a stiff bristled deck brush to agitate cleaner on the surface. [A cotton mop is not recommended since pieces of mop may get caught on high profile of DURABAK™ surface.] A synthetic fiber material mop may be used if a deck brush is unavailable.
2. Rinse surface thoroughly to remove all residue.
3. Remove all water with a sponge mop, a 24 oz. mop or water vacuum.

ALTERNATE METHODS

For larger areas, where the above method is not time efficient, there are alternatives available to expedite cleaning.

PRESSURE WASHER

A wide-angle water pressure spray of 600-700 PSI can clean DURABAK™ without damage to the surface.

ROTARY MACHINE

A rotary 14” waxing-type machine with a (thickline) blue pad can be used.

RINSE-FREE DETERGENT

If a rinse-free detergent is used, the dirty water pickup can be done with a water vacuum.

AUTOMATIC SCRUBBERS

DURABAK™ surfaces can also be cleaned with automatic scrubbers. These are machines which, in one pass, put down the washing solution, scrub the floor with a (blue) pad, and vacuum up the dirty water. The pad pressure used in the scrubber (using a blue pad) need only be sufficient for the pad to make light contact with the floor. Heavy scrubbing over time will negatively affect the DURABAK™ surface.

SPECIFIC CLEANING ISSUES

GREASE SPILLAGE

To clean a DURABAK™ surface of a greasy or slippery solution, it is necessary to use a slightly more aggressive detergent, containing a degreaser, available from chemical suppliers.

REMOVAL OF STICKY SUBSTANCES

For removal of gum or other sticky substances from a DURABAK™ surface, use a pressure washer. A wide-angle water-pressure spay of 600 to 700 PSI, at an angle of 35-40 degrees, should enable the removal of gum pieces within 10 to 15 seconds without damage to the DURABAK™ coating.

REMOVAL OF ORGANIC STAINS

Organic stains, such as leaves, can be removed using a quatinary or a slightly acidic cleaner with a neutral pH. Leave on for five or ten minutes. Rinse off according to manufacturer’s recommendations. This will only work if the stain has occurred after DURABAK™ has fully cured.

CHLORINE

If left on the DURABAK™ surface, concentrated chlorine will discolor DURABAK™. Immediately rinse off the concentrated chlorine with water.

REPAIRING OR OVERCOATING DURABAK™

DURABAK™ can easily be repaired or over-coated (once cured), as it bonds to itself.

• Cut out all damaged DURABAK™ to eliminate uneven edges.
• Clean dirt from area to be repaired and rough up surrounding DURABAK™ with 60-grit sand paper.
• Clean area with Xylene.
• On exposed surfaces to which DURABAK™ does not bond easily, a primer may be needed.
• Brush, roll, or spray fresh DURABAK™ onto cleaned areas, as per application instructions.
  

ACCELERATOR

A liquid accelerator (available from COTE-L or an authorized DURABAK™ dealer) can be used to reduce the drying/curing time by up to 75%, depending on the climatic conditions. This may be helpful in areas of low atmospheric moisture, or when shorter curing/drying times are required. The accelerator comes in premeasured packets, one for quarts and one for gallons.

DIRECTIONS

• Contents of accelerator should be added to the DURABAK™ can upon opening, at the ratio of one quart-packet per quart, or one gallon-packet per gallon.

• The mixture should be stirred thoroughly to assure complete blending, then apply as per DURABAK™ regular instructions.

• Accelerator will not affect product performance. It will only speed drying and curing time.

SILICON CARBIDE

For added slip resistance in very wet conditions or extreme slopes, 60-grit silicon carbide can be broadcast onto the top coat of the DURABAK™ application.

DIRECTIONS

• Use a simple flour covered with a stretched piece of old stocking to facilitate the application.

• The silicon carbide should be applied immediately after the top coat DURABAK™ has been laid and while it is still very wet.

• Sprinkle the silicon carbide lightly over the wet DURABAK™, as evenly as possible.

• One ounce of silicon carbide will cover approximately eight square feet of DURABAK™.

METCOTE™ is a quick-drying single-pack anti-corrosion heat-resistant etch primer polyvinyl butyral coating for non-porous surfaces. It can be used on iron, steel, aluminum, fiberglass and galvanized metal.

NOTE: METCOTE™ cannot be used for surfaces which will be submerged under water.

PRODUCT USES

• Primer for DURABAK™ and DURABAK 18™

• Primer for metal and fibreglass surfaces

• Heat resistant metal coating (up to 428oF)

• A postblast primer on steel work

NOTE: Not for submerged surfaces.

ADVANTAGES

• One part

• Excellent adhesion to metal

• Quick drying (30 minutes at 77oF)

• Can be topcoated with most paints after dry

• Economical

• Good resistance to acid, alkali and water

• Non-flammable when cured

• Shelf life 2+ years. Once opened, can be reclosed and will remain useable for a long period afterwards. If product begins to thicken, it can be thinned with lacquer thinner, MEK, Propanol, Acetone or other similar polar solvents.

COLOR

Black

COVERAGE

Approximately 145 sq. ft./quart

SURFACE PREPARATION

All surfaces must be clean of dirt and release agents, dry, firm and free of rust and mill scale. All surfaces should be roughened. METCOTE™ will provide a fair bond to smooth surfaces, but roughening the surface will greatly improve adhesion.

IRON

Abrade the surface with 100-360 grit sand paper. If abrasive blasting is desired, the blast profile should not exceed 50 microns (or 2 mils).

GALVANIZED IRON

Wash with a galvanized iron cleaner until a water break free surface is obtained (i.e. no beading). Rinse with clean water.

ALUMINUM

Abrade with 220 grit sandpaper, then rinse with solvent.

NOTE: The finished surface on all substrates should have a scored, roughened profile for best adhesion.

APPLICATION

• Stir METCOTE™ well.

• Apply thinly (less than 1.7 mils) by brush or roller.

• For conventional spray application, thin with lacquer thinners (approx 20%) to 16-20 secs (Ford Cup 4).

APPLICATION TEMPERATURE

23oF to 122oF

NOTE: Lacquer thinners must not come into contact with DURABAK™ or DURABAK 18™. Allow METCOTE™ to dry completely before overcoating with either DURABAK™ or DURABAK 18™.

OVERCOATING

Allow a minimum of 30 minutes (at 77oF) to a maximum of two weeks. When applying any polyurethane coating such as DURABAK™, METCOTE™ must be completely dry before overcoating. If dirt or other contaminents get onto the METCOTE™ surface, clean with water and detergent or turpentine (do not use xylene) and dry thoroughly before applying DURABAK™ or DURABAK 18™. If top-coating after 14 days, lightly abrade METCOTE™ surface.

IMPORTANT ADVICE

• Observe safety precautions as noted on can.

• Use lacquer thinners.

• WARNING: Do not use the same brush, roller, or spray gun for applying DURABAK™ or DURABAK 18™. Wet lacquer thinners will prevent DURABAK™ or DURABAK 18™ from bonding.

LIMITATIONS

• When used for exterior use on iron, the product must be topcoated within 14 days, to prevent corrosion.

• The Dry Film Thickness must be kept at 1.2 mils or less, especially if the topcoat has strong solvents.

For additional technical assistance
contact yourDURABAK™ distributor
or COTE-L Industries, Inc.

COTE-L Industries, Inc. 1542 Jefferson Street Teaneck, NJ 07666 E-mail		Tel: (201) 836-0733 Fax: (201) 836-5220

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