Method Statement for Epoxy Resin Coating Works for Floor

method statement epoxy coating for floor

What is the method statement for epoxy resin coating for the floor?

The method statement for epoxy resin coating for the floor defines the sequence, quality control procedures and safety guidelines for epoxy flooring works.

This work method statement covers activities related to epoxy floor coating works on various locations as applicable and excluding traffic/vehicular areas.

Definitions

Developer/Client-xxxx
Supervising Consultant-xxxx
Main Contractor-xxxx
QC-Quality Control
HSE-Health Safety & Environment
PPE-Personal Protective Equipment

References

Project Specifications
Contract Specifications
Architectural Specifications
Epoxy Resin Floor Coating
Health and Safety Plan
Construction and Environmental Management Plan

Epoxy floor coating at the industrial ground floor areas

Responsibilities

1. Project Manager

Responsible for accomplishing the stated objectives which include creating clear and attainable objectives, building the requirements, and managing the cost, time, scope, and quality.

2. Site Engineer

Supervise operations in accordance with the approved method statement, shop drawings, specifications, approved material submittal, and schedules to achieve the acceptance of the deliverables.

3. Site Foreman

To liaise with the Site Engineer and Supervisor for the work execution.

4. HSE Manager

Health, safety, and environmental (HSE) managers generally plan, coordinate and implement issues and directives within the organization.

They ensure safe environmental working conditions for all employees.

5. HSE Supervisor/Officer

The Safety Engineer should be full-time at the site and should frequently visit all the ongoing activities.

All safety violations and on-conformance of the plan shall be registered and immediate action will be done in coordination with the Site Engineer.

6. Scaffolding Manager/Supervisor

Ensuring safe access is provided for scaffolders’ jobs.

Ensuring that all his foremen, construction team leaders, construction staff, and workers are conforming to work safety regulations and are Third Party Certified (TPC).

Ensuring that all scaffolds are erected according to scaffold methods.

Ensuring that scaffold schedules are met and still working within the safety requirement.

Ensuring that material and workers are available to meet the scaffolding requirements.

Ensuring that all documentation adheres to ToolBox Talks, Harness Inspection, Work Request System, Scaffolding Tagging System, and Safety reports.

7. QA/QC Engineer should ensure are ongoing as per specifications and the document should follow as per ITP.

8. Tradesmen (Workers)

The workers should aware of the nature of the job and should know the approved system, however, the tasks and the quality must be ensured by the site engineer and QA/QC Engineer.

Resources

Tools and Equipment

Approved scaffolding-For working at height
Confined space rescue-For emergency rescue
Multi-gas detector-For gas test inside confined space
Lighting facilities-For lighting of job area
First aid box-For emergency first aid
Exhaust fans-For ventilation
Barricading and fencing-For preventing unauthorized access
Protective clothing (gloves, overalls, goggles, and face masks)-For safe working
Slow speed drill, 400 or 500 rpm, plus mixing paddle and mixing vessel-For mixing
Grinder & vacuum cleaner-For surface preparation / floor preparation
Rollers, scrappers & brushes-For painting application

Workforce

Site Engineer
QA/QC Engineer
HSE Officer
Team Leader/Foreman
Technicians
Applicators

Light Tools

Drill Machine
Slow speed drill machine
Surface Grinder
Hand Grinder
Vacuum Cleaner / Dust Collectors
Industrial vacuum machine

Materials

Epoxy Paint Application–Sikafloor 264 – Approved material
Floor Putty–Sikafloor PS
Aggregates–Sikadur 507

Methodology-Epoxy Coating Works for Floor

General

This methodology specifies the requirement for 2 coats of epoxy flooring in concurrence with the manufacturer recommendations, requirements, and other related detail specifications.

The working area will be barricaded and restricted from the entry of unauthorized personnel.

It will be properly illuminated and necessary warning signs to be installed in the proper location.

All scaffolding activities and ladders for access and egress will be erected by certified scaffolders. All erected scaffolding access and egress will be inspected and tagged prior to use.

The relevant permits to be fully complied with by the working team prior to commencing activity and ensure its validity.

Part mixing is acceptable as per requirements. However, once the pack is opened and not in use this must be tightly sealed with the lid (material to be checked prior to the next usage).

All workers to be involved in the activity will receive proper information, instructions, training, and adequate supervision during the activity. All workers will be briefed as well with the safe system of task and procedure along with the use of proper PPE’s and emergency rules.

Relevant entities which might need protection include any type of work in the area vicinity of work, service access, or discharge path.

Procedures-Surface Preparation

The existing area which requires refurbishment must be prepared to ensure a strong adhesive bond between the first coat and the existing concrete area.

Clean the surface by grinding means of heavy-duty substrate grinders to remove the previous coating, laitance, and other contamination such as oil, grease, mortar and paint splashes, etc. (Any sharp edges, protrusions, imperfections, or surface undulations in levels to be ground and made well by the client free of charge.)

surface preparation prior to application of epoxy floor coating
Surface preparation prior to epoxy resin floor application

Vacuum clean to remove the dust and other loose particles.

Before application, all surfaces must be dry and free from oil, grease, decayed matter, moss or algae growth, and general curing compounds. All such contamination and laitance should be removed by the use of mechanical means.

The surrounding surfaces which are not to be coated but which may be affected by the coat application should be protected.

Fill all exposed blow holes, routed out cracks, etc. with SIKAFLOOR PS up to a rate of 0.1 to 0.2 kg/m² to obtain a uniform surface of texture similar to medium sandpaper.

Substrate Pre-treatment

The concrete substrate must be sound and of sufficient compressive strength (minimum 25 N/mm2)
with a minimum pull-off strength of 1.5 N/mm2.

The substrate must be clean, dry, and free of all contaminants such as dirt, oil, grease, surface treatments, etc.

Concrete substrates must be prepared mechanically using abrasive blast cleaning (blasting method) or scarifying equipment
to remove cement laitance and achieve an open textured surface.

Weak concrete must be removed and surface defects such as blowholes and voids must be fully exposed.

Repairs to the substrate, filling of blowholes/voids and surface leveling must be carried out using appropriate products from the Sikafloor, Sikadur, and Sikagard range of products.

All dust, loose and friable material must be completely removed from all surfaces before application
of the product, preferably by brush or industrial vacuum.

Epoxy Paint (Sikafloor 264) Implementation

SIKAFLOOR 264 is a two-part High-build Solvent Free Epoxy Coating. Suitable for use in hot and tropical climatic conditions.

Stir separately components A and B of SIKAFLOOR 264 well with an electric mixer, add the full contents of component B into component A, and mix with a slow speed mixer (300–400 rpm) for at least 2 minutes until a homogeneous mixture is achieved.

Place mixed material into a clean container, mix again for one minute.

Prior to the application of epoxy – SIKAFLOOR 264, the surface should be thoroughly cleaned to remove any traces of dust or other debris.

Apply the primer to the prepared surface prior to utilization of floor putty.

Afterward, apply the epoxy mixed material by roller using the consumption of 0.25 kg/m², taking care to ensure good wetting of the substrate but avoiding puddles on the surface. Allow drying.

Followed by the second coat of SIKAFLOOR 264 using a roller or brush at a rate of 0.25 kg/m² ensuring that the surface is fully covered and that no ponding of the material occurs. The coat should be applied evenly over the floor surface to ensure a regular film thickness.

The minimum interval between the coats is as follows:

Before applying layers of Sikafloor 264

Substrate TemperatureMinimum IntervalMaximum Interval
+10°C24 hours 3 days
+20°C 8 hours 2 days
+30°C 6 hours 1 day

Freshly applied SIKAFLOOR 264 should be protected from dampness, condensation, and water for at least 24 hours. Due to the nature of the activity, for damages on the finished surface, rectification will be done as per manufacturer recommendation which will depend on the type of damage.

Droppings and other foreign matters on different surfaces will be removed and cleaned immediately after the completion of each application.

epoxy paint application on flooring
Application of epoxy paint on the flooring

Thickness and Application Rate

Effective Covered Area
Sikafloor PS-0.200 kg/m²
Sikafloor 264 (1st coat)-0.250 kg/m²
Sikafloor 264 (2nd coat)–0.250 kg/m²

Types of Damages and Remedies

High spots to be removed by means of grinding by the use of the grinding machines.

All dust, loose and friable material must be completely removed from all surfaces before application of the product, preferably by brush and/or industrial vacuum.

The substrate and uncured floor must be at least 3°C above the dew point to reduce the risk of condensation or blooming on the floor finish.

Low temperatures and high humidity conditions increase the probability of blooming, thus weather conditions should be monitored always prior to any kind of coating.

Over mixing must be avoided to minimize air entrainment, since pot life of any kind of epoxy to be followed as per technical data sheet thus the area to be calculated prior to mix the material else it will lead to overconsumption or wastage.

Damage area should be found and analyze the root cause for repair, then the area to be repaired should be square cut and repeat the same application procedure, however, due to material property the color difference may occur.

Risk Assessment-Method Statement for Epoxy

Please refer to the attached document in Appendix A.

Inspection and Test Plan

Refer to Appendix B for Inspection & Test Plan

Drawings

Not applicable since the coating applications will be followed as per specifications.

Pre-Start Safety Briefing Arrangements

Refer to Risk Assessment on Appendix A.

Protective and Safety Equipment

All workers involved will be equipped with adequate PPE as stated below:
a. Safety Helmet with company logo
b. Safety Boots
c. High Visibility Vest
d. Safety Goggles
e. Hand Gloves
f. Coveralls

Information to Personnel

a. Safety Induction
b. Job Training
c. Superintendents Notices/Memos
d. Toolbox Talks
e. STARRT Card

Supervision and Monitoring Arrangements

Construction Manager

He is in charge of all construction activities. Schedule the site in logical steps and budget time required to meet deadlines. Inspect and review works to monitor compliance with building and safety codes and other regulations.

Site Engineer

The Site Engineer will evaluate the number of materials consumed by each trade to be compared against the planned quantity.

Site Foreman

A site foreman is responsible for supervising the workers and also doing actual activity. The foreman monitors employees to make sure that the work is done efficiently and within quality standards.

Chief Surveyor

A Chief Surveyor ensures that surveying data are collected and recorded accurately and that all company guidelines are followed by crew members.

QA/QC Engineer

The QA/QC Engineer will monitor whether the installation activities are conforming to the required quality otherwise he should notify the Site Engineer should he find non-conformance to the ongoing construction activities.

The Site Engineer should immediately rectify the work to avoid receipt of non-conformance from the quality engineer.

HSE Engineer

The Safety Engineer will be full-time at the site and will frequently visit all the ongoing tasks. All safety violations and non-conformance of the HSE Plan will be registered and immediate action will be done in coordination with the Site Engineer.

Scaffolding Manager/Supervisor

Ensuring that all his Foremen, Team Leaders, and workers are conforming to safety regulations and are Third Party Certified (TPC).

Ensuring that all scaffolds are erected according to scaffold methods.

Note: Site Engineers/HSE staff should have access on-site to civil method statements and risk assessment

Environment and Quality Issues

Precautionary Measure

All precautionary measures will be briefed to all workers prior to commencing the activity.

Disposal Requirements

All waste will be disposed of as per the Construction and Environmental Management Plan, and as per government-approved disposal areas.

Inspection, Test, and Sampling

Request for Inspection and Testing will be submitted prior to and after execution of works.

Quality Assurance Requirements Table

Ensure that work is executed as per approved shop drawing, method statement projects, and records are generated referring to approved ITP.

Best management practices should also be considered which may be stated by product manufacturers or suppliers.

Authority requirements will take precedence over all requirements in case authority approval is to be secured.

For non-authority approval activities, the approved latest specification will take precedence.

It is to ensure that regular toolbox pieces of training-related work quality are conducted and records are maintained.

List of Appendices

Appendix A: Risk Assessment
Appendix B: Inspection and Test Plan (ITP)
Appendix C: Permit to Work
Appendix D: Technical Data Sheet (TDS)
Appendix E: Material Safet Data Sheet (MSDS)
Appendix F: Material Compliance Sheet
Appendix G: Sika Confirmation Letter for Surface Preparation

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