Apply Masonry, Concrete, or Garage Floor Coating

A. Finished-Project Specification

Scope: one controlled masonry wall section, concrete panel, or garage-floor practice slab, prepared, patched, profiled where required, primed or sealed, coated, and inspected as a single documented system. Build one option only; do not mix substrate options within a single coated area.

B. Substrate Option Schedule

Option	Typical Defects Addressed	Coating System
Masonry wall	Efflorescence, mortar-joint deterioration, surface contamination, hairline cracking	Masonry primer/sealer and compatible masonry topcoat per the approved specification
Concrete panel	Surface contamination, minor spalling, hairline cracking, existing sealer	Concrete primer/sealer and compatible protective or decorative coating per the approved specification
Garage-floor slab	Oil and tire contamination, moisture vapor transmission, minor spalling, expansion joints	Moisture-tolerant primer, two-part floor coating, optional aggregate or flake broadcast, optional clear topcoat

C. Repair and Coating Takeoff

• Patch material: quantity sufficient to fill every recorded crack and spall to the manufacturer's specified depth and cure profile.
• Primer/sealer: quantity calculated from measured surface area and the product's stated coverage rate, with a minimum 10 percent waste allowance.
• Floor/masonry coating: quantity calculated the same way, matched to the specified film thickness and number of coats.
• Decorative aggregate/flake (if specified): quantity per the broadcast rate stated in the approved coating specification.

D. Acceptance Standards

Check	Standard
Moisture and alkalinity	Recorded test result at or below the coating manufacturer's stated limit before any product is opened
Contamination	No detectable oil, existing sealer, or curing-compound residue remaining after degreasing, confirmed by the specified test method
Surface profile	Matches the manufacturer's stated profile requirement where mechanical or chemical profiling is specified
Repairs	Every recorded crack and spall patched, cured, and inspected before primer; movement joints unbridged
Coverage	Primer, sealer, and coating applied within 10 percent of the specified coverage rate, with no thin spots or pinholes
Adhesion	Cured coating passes the specified adhesion check with no lifting, blistering, or delamination
Slip condition	Finished texture matches the specified slip-resistance requirement for the coating's intended use

E. Substrate Selection and Document Review

1. Select the approved substrate option: masonry wall, concrete panel, or garage-floor practice slab. Record the selected option on the Substrate and Coating Record.
2. Review concrete age, cure, moisture, alkalinity, contamination, vapor transmission, existing sealer, profile, coating, and slip-resistance requirements. Record every value stated in the approved coating specification.

F. Moisture and Contamination Testing

1. Perform the specified moisture and surface tests. Run the calcium chloride or in-situ test and the pH test at a minimum of two locations, including one near an exterior wall or below-grade area if present.
2. Test for existing sealers, oils, curing compounds, and contaminants. Use the specified test method (water-droplet test or manufacturer-specified method) and record the result for each test location.
3. Stop work when moisture or contamination exceeds the coating limits. Record the excess condition and the required correction, drying period, or professional referral before proceeding.

G. Cleaning and Profiling

1. Protect adjacent walls, drains, doors, equipment, and landscaping. Mask or cover surfaces that must remain free of degreaser, etching solution, or coating overspray.
2. Degrease and clean the substrate. Apply the specified degreaser and scrub with a stiff brush, working from the least to the most contaminated area.
3. Rinse and dry according to the product. Confirm the substrate reaches the manufacturer's specified dry condition before profiling.
4. Mechanically profile, grind, shot-blast, or acid-etch only where the approved system requires it. Do not profile a substrate the specification does not call for profiling.
5. Use silica, chemical, ventilation, and wastewater controls. Operate HEPA-filtered extraction during grinding or shot-blasting and neutralize etching solution per the product instructions.
6. Do not discharge acidic or contaminated rinse water improperly. Contain and dispose of rinse water and slurry using the approved method.
7. Vacuum dust and neutralize residues where required. HEPA-vacuum all profiling dust and confirm neutralization with a pH check where acid-etching was used.

H. Repair and Cure

1. Repair cracks, spalls, and surface defects with compatible products. Fill each recorded defect to the manufacturer's specified depth and finish.
2. Preserve active movement joints. Do not fill, bridge, or coat over a joint identified as an expansion, control, or isolation joint.
3. Allow repairs to cure. Observe the patch product's stated cure time before proceeding to profile verification.
4. Verify the required surface profile. Confirm the cured, repaired surface still meets the manufacturer's stated profile requirement at each repair location.

I. Primer, Coating, and Broadcast Application

1. Apply primer or sealer at the specified coverage rate. Mix per the manufacturer ratio and apply by roller, squeegee, or brush as specified.
2. Observe induction, pot life, and recoat limits. Do not apply the floor coating before the primer's minimum recoat time or after its maximum recoat window.
3. Mix the floor coating accurately. Combine components in the exact ratio and for the mixing time the manufacturer specifies.
4. Cut edges and detail penetrations. Apply the coating along walls, drains, columns, and other penetrations before working the field area.
5. Roll or squeegee field areas at the specified rate. Spread the coating using the notched squeegee, then back-roll with the phenolic roller to the specified film thickness.
6. Broadcast aggregate or decorative flakes only where required. Broadcast into the wet coating at the specified rate using spiked shoes to access the field area.
7. Back-roll for uniform film. Maintain a consistent wet film thickness across the entire coated area.

J. Cure, Additional Coats, and Inspection

1. Protect the surface through cure. Block access and control dust, moisture, and foot traffic until the coating reaches its specified cure stage.
2. Apply additional coats or clear topcoat within the recoat window. Recoat only within the manufacturer's stated window; extend surface profile by light sanding if the window is exceeded and the product requires it.
3. Inspect adhesion, pinholes, bubbles, fish-eyes, thin spots, roller lines, gloss, slip texture, and movement joints. Perform the specified adhesion check and record the condition of every listed item.
4. Document moisture, profile, batches, coverage, cure, and inspection. Complete the Substrate and Coating Record with every test result, batch number, and inspection finding.