Home › Solutions › Residential › Resin Rustic™ › Resin Rustic Installation Guide

How to apply decorative epoxy flooring

The following guide includes hints, tips and instructions for installing the decorative epoxy flooring system
manufactured by Real World Epoxies - Resin Rustic™

1. Surface preparation

Contaminated concrete:

To determine if the concrete is contaminated with oil or grease, drip a small amount of water onto the surface. If the water beads, the concrete should be before any other surface preparation is performed.

Painted or sealed concrete:

Previous paints or sealers should be removed with a diamond grinder prior to application.

Moisture in concrete:

Inspect surface for signs of dampness or efflorescence. If there are no visible signs, test with a moisture meter. If the moisture content exceeds 5.5% or there’s a relative humidity of 70% or greater, apply a moisture barrier.

Loose concrete and dust:

Ensure all loose material is removed from the surface and damaged areas are repaired prior to application.

Flatness:

For best results, the substrate should not deviate more than the following distances under a straight edge tool:

• 3mm over 3m (flatness),
• 1mm over 150mm (smoothness),
• 0.5mm over 50mm (projections).

If required, the substrate should be levelled first with a suitable levelling compound.

Cracks:

Fill static cracks, divots and gauges with a suitable patching compound, e.g. Ezypoxy Clear with Ezypatch filler. Dynamic cracks should be filled first before cutting out to form a control joint. The joint should be sealed with a suitable flexible joint sealant after application of the flooring system.

New concrete:

Allow concrete to harden for 28 days before conducting surface preparation as per the instructions below.

Preparation instructions:

Diamond grind to obtain a clean, granular/rough feel with a CSP 2-3 profile. Use a Schmidt hammer to test hardness of concrete so that the right disc segments can be chosen (e.g. hard or soft bond).

Properly prepared surfaces should be structurally sound and free of contamination, laitance and any loose material. Ensure prepared surface is clean, dry and dust-free again if there’s a delay between preparation and application.

Porous surfaces:

If the concrete is found to be particularly weak, powdery or porous during substrate preparation, apply a suitable primer/sealer, e.g. Ezypoxy Clear, to prevent the first coat from soaking in too much.

2. Setting up

Read these instructions in full before getting started.

Get all tools and the mix area ready before mixing. The mix area shouldn’t be too far away, cordoned off if possible and with product laid out neatly (in a cool place, away from direct sunlight). Make sure it’s big enough to allow plenty of room to move and work cleanly.

Use drop sheets to protect all surfaces from splashes/spills/drips, and have plenty of lint-free cotton rags and solvent for clean-up. It should also contain a separate clean area and a waste bin for discarded items.

3. Plan first coat - Ezypoxy Rollcoat

Each kit of Ezypoxy Rollcoat will cover approximately 60m² @ 200 microns (5m²/L).

Plan progress across the area. Consider how to finish kits, using joints as boundaries and keeping edges fresh so the next kit can be seamlessly worked in. Large joints should never be covered because cracks can appear. Apply up to the edge and let it run into the joint instead of trying to fill or cover completely. Flexible sealants can be used if desired after application is complete.

Mark out sections of the floor with masking tape as a guide to help you use the correct amount and achieve correct film thicknesses. Use this time to mask up any surfaces you wish to protect from accidental contact with the resin, e.g. skirting boards, drains, transition strips etc.

4. Mix Ezypoxy Rollcoat

WARNING: Part B is a Class 8 Corrosive. For full safety instructions, consult SDS. Wear protective clothing, goggles and gloves to prevent skin and eye contact. Clean up can be made using methylated spirits or acetone.

Pre-mix pigment pot into Part A first with a drill using a Jiffy mix blade. Pour Part B into Part A and mix for 2 minutes or until a consistent colour is obtained, scraping sides to ensure all product is taken in.

For grey colours - Iron Grey, Pearl - use Light Grey Pigment Pots.

For tan colours - Oyster, Oatmeal - use Merino Pigment Pots.

For all other colours, use Black Pigment Pots.

Mixing notes:

• Unused Part A can have a solid-looking gel consistency that only starts to flow once mixed.
• Do not leave container in direct sunlight as heat will accelerate hardening reaction.
• To help mixing process in cool temperature (below 10^oC), warm the components separately in hot water to 25^oC beforehand. Over-heating the product will result in a significant reduction in pot life.
• If more than one kit is mixed at a time, the hardening reaction can generate high temperatures and significantly reduce the pot life.

5. Apply Ezypoxy Rollcoat

Start in the far corner, progressing across the room and back towards the point of exit.

When pouring, start approximately 50cm from a wall and work towards the exit point pouring in an “S” shaped pattern.

Leave enough to cut in around tight areas with a brush. Try not to cut in too far, just enough to protect the vertical surfaces.

Perform a rough spread using the squeegee, allow product to level for 2-3 minutes, then backroll smooth using 12mm roller covers. When backrolling, aim for long, even, overlapping strokes to get the product feeling and sounding the same. The film will often make a soft tearing sound when rolled evenly. For best results, roll the film perpendicular to the first direction to finish.

It’s a good idea to de-lint all rollers first by wrapping the roller in masking tape and removing. Repeat this process, fluffing the roller in between until there are no fibres visible on the back of the tape.

To work a fresh batch into the seam of another, pour the material approximately 15cm from the edge and overlap with the roller by about 30cm. Try to minimise the number of seams and keep them as fresh as possible. If left for too long, pigments can settle and lead to a visible colour difference.

Each kit must be applied within the pot life times listed in the Cure Schedule table to ensure best results.

Table - Ezypoxy Rollcoat Cure Schedule

Temperature	Pot Life	Re-coat	Light Traffic
15oC	40 min.	36-48 hours	48 hours after final coat
25oC	20 min.	18-24 hours	24 hours after final coat
35oC	10 min.	9-12 hours	24 hours after final coat

Application tips:

• Do not apply in temperatures lower than 5^oC.
• If a puddle of product is left to sit on the floor for a few minutes, it may need to be worked around briefly with a trowel before rolling to loosen gelling effect.
• Selection of roller cover can have a big impact of the quality of the finish, especially when it comes to errant fibres. Only use quality, lint-free roller covers.
• The 200-micron film creates a rippled texture and semi-gloss finish.
• Cut in with a brush or small trowel. Pour a thin bead of resin approximately 5-10cm from the edge and use the brush to spread it evenly into place.
• The listed coverage is the maximum for one Ezypoxy Rollcoat kit. Kits can be split and used across smaller areas by using the following weights and volumes to make 1 litre:



Part A	Part B
880g/660mL	350g/340mL

6. Smooth surface

Once the first coat is hard enough (see Re-coat Times in the Ezypoxy Rollcoat Cure Schedule table), carefully walk back on the floor and use sand paper to remove any peaks. Using a sanding pad attached to a extension pole works well for this task. This will ensure a smooth finish overall and makes it easier to apply the second coat. Use a dust mop and solvent
wipe the floor afterwards to pick up all the loose bits and dust.

7. Plan second coat - Rustic Topping

Each batch - Artepoxy Liquid Crystal, RWE Rustic Filler and Artepoxy Effect Pigment Pot - will cover approximately 9m² @ 2000 microns/2mm (0.5m²/L).

Plan application as per first coat.

8. Mix Rustic Topping

WARNING: Part B is a Class 8 Corrosive. For full safety instructions, consult SDS. Wear protective clothing, goggles and gloves to prevent skin and eye contact. Clean up can be made using methylated spirits or acetone.

Pre-mix filler and pigment pot into Part A first with a drill using a Jiffy mix blade. For best results, let product sit for 30 minutes to allow resin to wet out. Pour Part B into Part A and mix for 2 minutes or until a consistent colour is obtained, scraping sides to ensure all product is taken in.

Mixing notes:

• Do not add more than one pigment pot to each Part A as it can adversely affect colour, design and/or finish.
• Make sure effect pigment is mixed well as undispersed lumps can be visible and affect quality of finish.
• As the product creates the shadowing effect through settling, only pour out freshly mixed product to avoid settling in the bucket and inconsistencies in design. Mix again if the bucket has sat for too long.
• Do not leave container in direct sunlight as heat will accelerate hardening reaction.
• If more than one kit is mixed at a time, the hardening reaction can generate high temperatures and significantly reduce the pot life.

9. Apply Rustic Topping

Follow same instructions as first coat with regards to starting point, cutting in, working with seams and achieving an even finish. Application can then be made with a spreading rake and stand-up trowel.

Each kit must be applied within the pot life times listed in the Cure Schedule table to ensure best results.

Table - Artepoxy Liquid Crystal Cure Schedule

Temperature	Pot Life	Re-coat	Light Traffic
15oC	40 min.	36-48 hours	48 hours after final coat
25oC	20 min.	18-24 hours	24 hours after final coat
35oC	10 min.	9-12 hours	24 hours after final coat

Application tips:

• Avoid pouring or spreading in lines as they will tend to be obvious when the shadowing/settling takes place.
• Aim to pour out and position quickly to avoid product settling too much before being spread, which can alter the design/patterning.
• Position topping using a 600mm spreading rake set at 2mm film thickness, then use the trowel to break up the pour lines and flatten the floor out. Keep the trowel in motion while applying, i.e. start and finish “on the dry”.
• If the product does settle before being spread, agitate with the trowel before spreading it out evenly once again.
• Do not apply in temperatures lower than 5^oC.
• Do not add solvents as it can affect performance.
• Resin Rustic is not designed to produce a perfectly flat, mirror finish on the floor.
• Cut in with a small trowel. Pour a thin bead of topping approximately 5-10cm from the edge and use the trowel to spread it evenly into place.
• For more information on how to get good results with decorative epoxy flooring, read our decorative epoxy flooring tips. 
• The listed coverage is the maximum for one batch of Resin Rustic Topping. Batches can be split and used across smaller areas by using the following to make 1 litre:
  
  

Part A	Part B
1440g/790mL	210g/210mL

Once completed, the floor will be ready for light traffic in 24 hours and reach full hardness over 7 days.

10. Storage

Keep containers closed when not in use. Store below 40°C. Do not store in direct sunlight. Shelf life is at least 12 months in original, unopened container. Seek advice from your local council regarding accepted disposal methods.

11. First Aid

CAUTION: KEEP OUT OF REACH OF CHILDREN.  IF ON SKIN: Remove immediately all contaminated clothing. Rinse skin with water. IF IN EYES: Rinse cautiously with water for several minutes. Immediately call a POISON CENTRE (Australia - 13 11 26) or doctor/physician. If skin irritation occurs: Get medical advice/attention. 

Our technical advice, whether verbal or in writing, is given in good faith but without warranty. This also applies where proprietary rights of third parties are involved. It does not release the user from the obligation to test the products supplied for their suitability in the intended processes and uses.

Download a copy of the installation guide - Resin Rustic™