Bulletin 104
Fundamentals for the Application of Epoxy Coatings

ALL OF THE FOLLOWING FUNDAMENTALS SHOULD BE FOLLOWED

1. Avoid, at all times, careless and haphazard application procedure.
   
   
2. Remove all catalyst from the container and mix VERY THOROUGHLY into the base. We strongly recommend the use of an electric mixer for proper mixing of any two-component material.
   
   
3. When using ZERON begin application immediately after mixing when temperature is 85 F (29.4 C) or above. Between 70 F and 85 F, (21.1 C and 29.4 C) wait 15 minutes before application begins. In cooler weather, 50 F to 70 F (10 C and 21.1 C), wait 30 minutes before applying.
   
   
4. Painting should never start if there is water, moisture, or dew on the surface, you can dry the surface with rags and start painting when surface is dry. Laying plastic on the surface will trap moisture and form condensation showing if surface is still damp. After several hours or days of hard rain the concrete will become saturated. Never apply paint to a saturated surface. Wait until the pool "drys out" and the dampness is no longer visible.
   
   
5. Avoid painting on windy days when dirt or dust may be deposited on the surface before it becomes tack free.
   
   
6. Never repaint a pool unless the painted surface has been scrubbed with #910 Pool Washing Compound or tri-sodium phosphate and acid etched.
   
   
7. Never paint new unpainted concrete until it is thoroughly etched and cleaned with a muriatic acid solution. Following the acid etching, the surface should be neutralized with tri-sodium phosphate and hosed off under pressure.
   
   
8. If there is a cement base masonry paint on the concrete surface it should be removed before painting, as it is a very questionable base. Muriatic acid will usually remove cement paint. Use our Bulletin #141 for acid etching. After removal, paint as bare or new concrete.
   
   
9. Do not apply paint over primer or a previous coat of paint until it has cured tack free. This can be ascertained by applying finger pressure on the surface.
   
   
10. Avoid the application of an additional coat when the existing coat has cured too long. If, for reasons beyond your control, the existing coat has cured too long, it will be necessary to scarify the surface with coarse sandpaper or the appropriate surface preparation tool. You can normally avoid waiting too long to recoat by consulting the curing schedule in Special Bulletin #105. Lines for racing lanes should be applied as soon as the paint cures to the point where it will take foot traffic without being tacky or marring the paint.
    
    
11. Never mix more than can be applied during the "pot life" period. Always store and mix in a cool place, as heat will detract from the "pot life" period.
    
    
12. Our epoxy coatings are packaged at the ideal viscosity for application. For spraying, add up to one pint of #1109 Epoxy Solvent per gallon for ZERON and up to one pint per gallon for POXOLON. An experienced spray operator will be able to judge spraying viscosity. In cooler weather they be thinned in order to provide normal application properties. Avoid overthining as this will result in (a) reduced paint film thickness, which could result in earlier deterioration of the paint and unsatisfactory performance, and (b) sags and runs. If overthinned, the viscosity can be raised to normal with the addition of unthinned but mixed paint of the same type. While different types of solvents can be used for "cleanup" or for cleaning equipment, use only #1109 Epoxy Solvent for thinning an epoxy coating.
    
    
13. Never repaint pools which are scaling, peeling, or blistering. If only a few small spots are scaling, these spots can be sanded and primed and then the entire pool can be recoated; otherwise, complete paint removal is necessary.
    
    
14. While the solvent blend used in our epoxy coatings has a flash point above 100 F, it is always necessary to have adequate ventilation when painting indoor pools.
    
    
15. Never try to "skimp" on primer. If the surface "soaks up" the primer, it should be reapplied until a uniform color is evident. Only prime bare or unpainted concrete. Primer is not required over previously painted surfaces.
    
    
16. CAUTION! Steps, shallow water and wading pools will become possible slipping hazards unless they are made slip resistant. This is done by very lightly sifting silica sand on the paint while it is wet.
    
    
17. In order to have consistent and satisfactory results from epoxy coatings, it is best to follow the information provided by the manufacturer. "Short cuts" and "time savers" could develop future problems. If the information provided herein is followed, problems will rarely exist.
    
    
18. Always use one gallon containers of ZERON on residential sized pools. Five gallon containers may "set up" before all the material can be used. Five gallon containers are for larger pools where the mixed ZERON can be applied faster by spraying or by two or more applicators.
    
    
19. Never repaint rubber base paint with an epoxy!
    
    
20. When applying epoxy coatings over previously applied epoxy coatings, it is necessary to do several preparatory functions if a good bond is to be achieved. The old epoxy coating should not be recoated until it is so thin it is almost transparent. Each year the coating will erode slightly until it becomes thin and somewhat transparent in spots. Then it should be scrubbed with #910 Pool Washing Compound or T.S.P. An acid wash will clean all chalky substances and stain from the surface. Hose off under pressure with clean water. After drying, the new epoxy may be applied. We suggest one coat of ZERON or two coats of POXOLON. Bare spots should be spot primed with appropriate primer. If the pool is recoated while there is a remaining thickness of epoxy coating, and it has not completely lost all of its gloss or is still smooth (after T.S.P. and acid cleaning), it should be sanded using coarse sandpaper and by sanding in one direction (not circular) until many fine lines are cut over the entire surface.
    
    

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    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