Mapei Mapefloor I 500W

Mapefloor I 500 W is a two-component multipurpose neutral-coloured epoxy formulate in water dispersion to create vapour-permeable coatings on industrial floors

Best Uses

Mapefloor I 500 W is a two-component epoxy formulate in water dispersion used to create self-levelling and/or multi-layered resin coatings permeable to water vapour with an attractive, smooth or non-slip finish for application to industrial floors. Mapefloor I 500 W is a water-based product it does not shrink, and the thickness of a dry layer is virtually the same as that of a wet layer.

Also, since Mapefloor I 500 W is a water-based product, it is safe for the environment and so particularly suitable for the foodstuff industry. After application, surfaces are seamless and flat with a highly attractive finish. Mapefloor I 500 W hardens even at low temperatures (around +5°C.) and may be applied on concrete after only 4 days of curing. Mapefloor I 500 W is strong, has excellent resistance to chemicals and abrasion and may be used in both self-levelling and multi-layered coating systems.

Application examples include:

• Coating floors in the chemical and pharmaceutical industries
• Coating floors in the foodstuffs industry
• Coating floors in laboratories
• Coating floors in mechanised warehouses
• Coating floors in shopping centres
• Coating floors with no vapour barrier
• Coating floors in underground car-parks

Application

Preparation of the substrate
The surface of concrete floors must be flat or with a maximum slope of 1.5%, clean and sound and have no crumbling or detached portions. The substrate concrete must have a compressive strength of at least 25 N/mm² and a minimum tensile strength of 1.5 N/mm². The strength of the substrate must also be suitable for its final use and the types of load to which it will be subjected. The surface of the floor must be prepared with a suitable mechanical process (e.g. shot-blasting or grinding with a diamond disk) to remove all traces of dirt and cement laitance and crumbling or detached portions, and to make the surface rough and absorbent. Before applying the coating, remove all dust from the surface with a vacuum cleaner. Any cracks must be repaired by filling them with Eporip, while any deteriorated areas of the concrete must be repaired with Mapefloor EP19.

Application of primer
The substrate on which Mapefloor I 500 W is to be applied must be wetted just before applying the product. Do not allow puddles or standing water to form on the surface. Mapefloor I 500 W must only be applied on damp, matt substrates. If the substrate also needs to be consolidated, apply a coat of Mapecoat I 600 W water-based epoxy primer. Priming the substrate is always recommended before applying Mapefloor System 53 self-levelling coatings.

Preparation of Mapecoat I 600 W primer
Pour component A into component B and carefully blend together with a low-speed mixer with a spiral mixing attachment until a smooth, even mix is obtained. Slowly dilute the product with water at a rate of up to 1:1 in weight and keep mixing. Spread the mix on the substrate with a medium-piled roller to form an even coat then lightly broadcast with Quartz 0.5 to ensure that the next coating of resin adheres perfectly.

Preparation of the product
Mix component A thoroughly and add the contents of component B. Add Mapecolor Paste (1.4 kg of colouring paste for each 26 kg kit of Mapefloor I 500 W) and mix again with an electric mixer at low speed to prevent entraining air into the mix (300-400 revs/min); add 2 litres of clean water while mixing. In cold weather the amount of water added to dilute the mix may be increased to up to 3 litres. In order to obtain an homogeneos colour finishing, dilute Mapefloor I 500 W with the same amount of water in all areas of the site. However, the pressure of water can cause light colour differences. Mix for at least 2 minutes until it is completely blended. Pour the mix into a clean container and briefly mix again. Do not mix the product for too long to prevent entraining too much air into the mix. Ocassionaly mix the material being left in the container during pouring phase.

Application of the product

Mapefloor I 500 W may be used to create non-slip coatings (3 to 5 mm thick) and self-levelling coatings (2 to 4 mm thick). Apply the mix within the pot life indicated in the table (refers to a temperature of +20°C). Higher surrounding temperatures will reduce the pot life of the mix, while lower temperatures will increase its pot life.

Application procedures:
1. Multi-layered non-slip coating - thickness approx. 3 mm (Mapefloor System 51)
Prepare the substrate as specified (we recommend shot-blasting or rough grinding with a diamond disk) and remove all dust with a vacuum cleaner. Wet the surface with Mapecoat I 600 W or apply an even coat of the product over the entire surface using a medium-piled roller then lightly broadcast with Quartz 0.5 so that the next coat of resin adheres perfectly. Prepare the Mapefloor I 500 W mix, pour it on the floor and spread it out evenly with a straight trowel or notched rake. Fully broadcast with Quartz 0.5. For particular requirements, such as if a higher degree of non-slip finish is required, sand with a larger particle size may be used. In such cases, the consumption rate of the next coat will be higher.

When the product has hardened remove any excess sand, sand the surface and remove the last grains of sand with an industrial-grade vacuum cleaner. Prepare the Mapefloor I 500 W mix, pour it on the floor and spread it out evenly with a straight trowel or notched rake. Go over the surface of the resin if required to even out the finish.

2. Multi-layered non-slip coating - thickness approx. 5 mm (Mapefloor System 52)
Prepare the substrate as specified (we recommend shot-blasting or rough grinding with a diamond disk)  and remove all dust with a vacuum cleaner. Wet the surface with Mapecoat I 600 W or apply an even coat of the product over the entire surface using a medium-piled roller. Then lightly broadcast with Quartz 0.5 so that the next coat of resin adheres perfectly. Prepare the Mapefloor I 500 W mix, pour it on the floor and spread it out evenly with a straight trowel or notched rake. Fully broadcast with Quartz 0.5. For particular requirements, such as if a higher degree of non-slip finish is required, sand with a larger particle size may be used. In such cases the consumption rate of the next coat will be higher.

When the product has hardened remove any excess sand, sand the surface and remove the last grains of sand with an industrial-grade vacuum cleaner. Prepare the Mapefloor I 500 W mix, pour it on the floor and spread it out evenly with a straight trowel or notched rake, then fully broadcast with the same quartz sand used for the previous layer. When the product has hardened remove any excess sand, sand the surface and remove the last grains of sand with an industrial-grade vacuum cleaner. Prepare the Mapefloor I 500 W mix, pour it on the floor and spread it out evenly with a straight trowel or notched rake. Go over the surface of the resin if required to even out the finish.

3. Smooth self-levelling coating - thickness approx. 2-4 mm (Mapefloor System 53)
Prepare the substrate as specified (we recommend shot-blasting or rough grinding with a diamond disk) and remove all dust with a vacuum cleaner. Wet the surface with Mapecoat I 600 W or apply an even coat of the product over the entire surface using a medium-piled roller then lightly broadcast with Quartz 0.5 so that the next coat of resin adheres perfectly. Prepare the Mapefloor I 500 W mix, pour it on the floor and spread it out evenly to the thickness required with a straight trowel or notched rake (with “V” shaped teeth). Backroll intensively with a spiked roller while the product is still wet to even out the thickness of the coat and to remove any air entrapped in the product.

It is possible to increase the resistance to abrasion of the surface and make it easier to clean by applying a coat of finish from the Mapefloor Finish range of aliphatic polyurethane products. In order to reach the best surface colour homogeneity apply one coats of Mapefloor Finish 59 W or Mapecoat I 62 W.