GENFLOOR · APPLICATION GUIDE
Floor Coating Application Guide
The steps to follow in epoxy, self-levelling and polyurethane floor systems, from surface preparation to putting the floor into service. The Gen Boya technical team is at your side for project-specific system selection and site supervision.
APPLICATION STEPS
A lasting floor starts with the right preparation.
28 days
MINIMUM CONCRETE AGE
< %4
SURFACE MOISTURE (CM)
≥ 1.5 N/mm²
PULL-OFF STRENGTH
+10 / +30 °C
APPLICATION TEMPERATURE
+3 °C
ABOVE DEW POINT
7 days
FULL CURE
01
Substrate assessment
The substrate is the first factor that determines coating performance. Before application, the age, strength and moisture condition of the concrete are measured and recorded.
—The concrete must have completed a curing period of at least 28 days.
—Surface compressive strength must be ≥ 25 N/mm² and pull-off strength ≥ 1.5 N/mm².
—Surface moisture must be below 4% (CM method). On floors at risk of rising damp, apply 642 Genfloor Moisture Barrier.
02
Mechanical surface preparation
Laitance, oil, curing membranes, old paint and loose layers are completely removed mechanically to obtain an open-pored, sound and rough surface.
—Shot blasting, diamond grinding or milling is recommended.
—Acid etching is not recommended; it leaves salts and moisture on the surface.
—Dust is removed completely with an industrial vacuum.
03
Repairs, levelling and joints
Cracks, holes and level differences are corrected before coating. The appearance and service life of the coating depend directly on the evenness of the substrate.
—Holes and breaks are filled with epoxy repair mortar made from primer and quartz sand.
—Expansion joints are carried through the coating and sealed with elastic sealant.
—Anchor grooves are cut at coating edges to prevent edge lifting.
04
Ambient conditions
Epoxy and polyurethane systems are sensitive to temperature and humidity. Conditions are kept under control throughout application and curing.
—Floor and ambient temperature must be between +10 °C and +30 °C.
—Relative humidity must be below 80%.
—Floor temperature must be at least 3 °C above the dew point.
05
Mixing
In two-component systems, correct mixing determines the chemical and mechanical resistance of the coating.
—Components A and B are mixed at the ratio stated on the packaging, emptying each container completely; partial mixes are not made.
—Mix for 2–3 minutes with a low-speed mixer (300–400 rpm), then transfer to a clean container and mix again.
—The mix is used within its pot life.
06
Priming
The primer seals the concrete pores and creates a lasting bond between coating and substrate.
—640 Genfloor Primer is applied evenly by roller or rubber squeegee; a second coat is applied on highly absorbent substrates.
—In self-levelling systems, 0.3–0.8 mm quartz sand is broadcast into the fresh primer to increase mechanical adhesion.
—On ceramic and tiled surfaces, 641 Genfloor Ceramic Surface Primer is used.
07
Intermediate and top coats
The system is selected according to the floor load and service conditions. Coat thicknesses and waiting times follow the values in the technical data sheet.
—In the roller system, 659 Genfloor Topcoat SF is applied in two coats.
—In the self-levelling system, 657 Basecoat and 660 Topcoat are spread with a notched trowel and de-aerated with a spiked roller.
—The recoat interval is approx. 12–24 hours at 20 °C; if exceeded, the surface is sanded.
08
Curing and return to service
The coating reaches its final strength at the end of the curing period. Early loading may cause permanent marks and damage.
—Foot traffic: after approx. 24 hours at 20 °C.
—Light traffic: after approx. 3 days.
—Full mechanical and chemical resistance: after 7 days. Times are longer at low temperatures.
09
Cleaning and maintenance
Correct maintenance prolongs the appearance and service life of the coating.
—Application tools are cleaned with the appropriate Gen thinner before the coating cures.
—Routine cleaning uses pH-neutral detergent and soft-brush machines.
—Chemical spills are cleaned up immediately.
10
Health and safety
Application is carried out in accordance with the product Safety Data Sheet (SDS).
—Chemical-resistant gloves, safety goggles and work clothing are worn.
—Adequate ventilation is provided in enclosed spaces; keep solvent-borne products away from ignition sources.
—Packaging and waste are disposed of in accordance with local regulations.