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What Caution Tape?

October 29, 2019

We’ve all been here a time or two. That fist clenching, eye rolling agony of someone stepping in that freshly broadcast floor coating. Whether a misstep by a broadcaster or another tradesman ripping through miles of caution tape only to be greeted by sticky feet —fret not because we have a solution. This blog will take you through the repair process of very small application marks in a Poly-Crete broadcast system.

The typical repair process for marks such as those depicted above would be a grind and re-broadcast (either of the entire space or treated as a small patch). This process can be time consuming, costly, and patches will always look like patches unless the whole area is done wall to wall.

So what can you do to fix a few small marks, such as a couple of foot prints or spike marks in your Poly-Crete floor, while keeping schedule and maintaining costs?

The first rule of thumb is to let the footprint or spike mark cure. Trying to fix the marks while the floor is still wet will just make matters worse.

STEP 1:  First, select the right tool for the job. For very small repairs we recommend using a Dremel type oscillating tool with the MM920 24 Grit Carbide Rasp attachment (or equivalent). This will give you maximum control and just enough touch to grind down the raised jagged edges level with the surrounding broadcast — without damaging the texture of the surrounding broadcast. A work light set at a low angle is absolutely critical in highlighting the raised edges of the application marks while grinding.

Figure 1: Shows the Dremel oscillating tool with the MM920 24 grit carbide rasp attachment used and an example of a soft wood paint stick
How to repair marks in resinous floor
STEP 1: The jagged raised edges of the center footprint and spike shoe marks are ground level using a Dremel oscillating tool equipped with the MM920 24grit carbide rasp attachment. A work light at a low angle is used to highlight the jagged raised edges to ensure that they are carefully ground level with the surrounding broadcast.

STEP 2:  After the jagged raised edges around the foot print or spike marks have been carefully ground level with the surrounding broadcast, vacuum out the dust and debris from the area.

Mix a kit of Poly-Crete TF-Plus in a color that matches the floor and prime the surface by lightly dabbing the prepared TF Plus into the low areas of the application marks. Next, utilizing the same mesh sand used for the broadcast, sprinkle some flint shot sand into the wet Poly-Crete TF Plus and work the sand into the wet TF Plus to form a mortar-like consistency.

Use the soft wood paint stick much like a trowel to screed, pat, and work the patch material into the low spots. The flat edge of the paint stick is used to pat the patch material down into the voids, while the long edge of the paint stick is used to screed off any excess material, taking care to leave the patch material level with the surrounding broadcast. A low angle work light is critical in highlighting high/low spots in the patch material.

polycrete tf plus repair
STEP 2: Poly-Crete TF Plus in matching color is lightly dabbed into the low spots to prime then flint shot sand is sprinkled in and mixed to form a mortar-like consistency. A soft wood paint stick works best to screed the excess Poly-Crete TF-Plus / Sand patch mixture level with surrounding broadcast. A work light at a low angle is necessary to highlight the high /low spots in the patch material that will be very visible when the grout/top coat is applied.

STEP 3:  Allow the Poly-Crete TF Plus & sand patch to cure stiff  before applying the topcoat, usually just a few hours at 70°F.

After repairs
STEP 3: Apply the grout / top coat over the repaired footprint and spike marks when patch material has cured stiff — typically takes a couple hours at 70°F. In this example a single topcoat of Poly-Crete Color-Fast was used, as the semi-gloss finish highlights the imperfections in the repair. The repaired area is highlighted by arrows. It’s important to manage expectations as the finish may not be perfect and some shading can still be present.

It is important to manage expectations, the finish will not be perfect and some shading will still be present. However with practice this repair process may provide a quick and simple fix for some situations that can eliminate the need for a more costly, time consuming grind & re-broadcast of a floor section.

The Dur-A-Flex Technical Service Team prides itself on being your go-to source for all things resinous floors. Don’t forget when in doubt, your technical services manager is just a phone call away and they will help you through any rough patches.

Author: Bret LePard
Bret is Technical Services Manager for the Midwest. His role involves working with customers to answer technical questions, troubleshoot issues and recommend the proper flooring system for their application.

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