Bulletin 100
ZERON Epoxy Coating as an Alternative to a Plaster Finish

ZERON is a heavy-duty epoxy coating that provides a smooth, easy to clean finish in swimming pools. This material may be used to re-finish rough, stained or worn out white plaster pool surfaces. It may also be used as an original finish on new gunite pools thereby eliminating the need for plaster.

The application techniques for re-finishing older pools with ZERON are shown in Bulletin #105. The following information deals with finishing new gunite and the application of epoxy coatings as an alternative to plaster in new pool construction.

FINISHING NEW GUNITE SURFACES FOR PAINTING

When ZERON is used in place of plaster, it is necessary to finish the newly gunited surface for painting. Many builders use different techniques for this purpose. You should use the method most suitable for your personnel and the one that you are able to perform the quickest. A "broom" finish is suitable.

When the gunite is shot and shaped with the knife or scraper, it is then wood floated. The object is to "smooth up" the newly gunited concrete as quickly as possible before the initial set has developed. An evaporation retardant can be used to control the rapid set of the concrete if it sets up too fast for easy floating. Occasionally during hot weather a light water spray is misted on the surface as it is wood floated. After wood floating and hand rubbing, the entire gunited surface must be acid cleaned to remove grit, laitance and other concrete components that float to the surface. This acid cleaning will remove unsound surface grit that could develop scaling at a future time. This acid should be hosed off under pressure. Neutralizing is not necessary as the alkali is the new concrete will do this. Rinsing the acid off with water should be done.

Any pits or depressions in the gunite may be filled with #962 Poxofill, which is an epoxy putty that may be trowelled and finished to a featheredge. High spots should be ground smooth and flush with a power grinder. When border tile is specified, a recess space should be cut in the gunite before it sets.

APPLICATION OF GUNZITE PRIMER

GUNZITE primer is a heavy bodied epoxy coat for new gunite. This material is applied with a paint roller and is used as a fill coat for the open pores in the new concrete surface. Press down on the roller when applying GUNZITE in order to squeeze the paint into the surface. Two coats may be necessary on unusually rough or porous surfaces. Follow label instructions for mixing catalyst and base components.

APPLICATION OF ZERON COATING

ZERON is a very thick epoxy coating, which is applied in one coat over primer. We recommend mixing the catalyst and base components with an electric drill equipped with a paint mixing attachment. Hand mixing is not as thorough or effective.

Apply ZERON with a paint roller equipped with a 1/2" nap, high-solvent resistant roller cover. Small areas may be trimmed with a brush.

MAXIMUM RECOATING TIME OF ZERON OVER GUNZITE:

24 hours @ 85°F and above
48 hours @ 84°F and below

POT LIFE:

     GUNZITE PRIMER
     2 hours @ 90°F to 95°F
     3 hours @ 85°F to 90°F
     4 hours @ 75°F to 85°F
     6 hours @ 68°F to 75°F
     8 hours @ 60°F to 68°F

     ZERON
     1/2 hour @ 85°F and above
     1 hour @ 85°F and below

CAUTION! During extremely hot temperatures ZERON MUST be stored in a cool place prior to mixing. Then do not mix more than one or two gallons at a time with no waiting period before application. It can also be thinned 5% to 10% with #1109 Solvent to lengthen "pot life".

CURING SCHEDULE:

     Before Filling Pool:

3 days @ 75°F and up
4 days @ 70°F to 75°F
5 days @ 65°F to 70°F
6 days @ 60°F to 65°F

Results may be improved by waiting a day or two longer.

DUST FREE DRYING TIME:

     1 hour @ 95°F
     1 1/2 hours @ 85°F
     2 hours @ 80°F
     2 1/2 hours @ 75°F
     3 hours - below 70°F

COVERAGE:

     GUNZITE Primer - 80 to 110 square feet per gallon
     ZERON - 150 to 175 square feet per gallon

CAN STABILITY:

     GUNZITE Primer - 2 years
     ZERON - 2 years

AGING PERIOD:
     After mixing and before application for: (See label under mixing)

APPLIED FILM THICKNESS:

     GUNZITE - 12 to 14 mils
     ZERON - 10 to 12 mils (one coat)

NOTE: When painting large pools, do not mix more than 5 gallons at one time. If it takes 45 minutes to use 5 gallons, mix another 5 gallons every 45 minutes, etc. Be sure to time your mixing schedule to allow proper "aging" period after mixing.

CAUTION!

Do not take internally. Close container after each use. Keep away from heat and open flame. Avoid prolonged contact with skin and breathing of vapor. Areas of body or clothing on contact with uncured resin and/or catalyst should be thoroughly cleaned with solvent and washed with soap and water immediately. Use only where there is adequate ventilation. KEEP OUT OF THE REACH OF CHILDREN.

Information herein given has been accumulated through many years of experience and verified by our technical personnel and is based upon tests believed to be reliable, but RESULTS ARE NOT GUARANTEED.

NOTE: KELLEY TECHNICAL COATINGS, INC. makes no implied warranty of merchantability, no implied warranty of fitness for a particular purpose and no other warranty, either express or implied, concerning its products.

KELLEY TECHNICAL COATINGS, INC.
Louisville, KY 40210