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Application Guide
Excel-Coat
Application Guide
Pedestrian Traffic Membrane
materials & Tools
MATERIALS
- Excel-Coat Primer 120 or PC-155
- Excel-Coat #1
- Excel-Coat #200
- Excel-Coat #300
- Excel-Coat Patching Compound
- Fiberglass (9 oz.)
- Urethane Sealant
- Excel-Crete K/D and Tinted Additive may be used as an alternate texture for increased skid resistance and durability
- Excel-Crete Retarder as needed for Excel-Crete texture
TOOLS
- Fiberglass Roller
- Hammer
- Razor Knife
- Wallboard Scraper
- Roller Frame
- Roller Sleeves
- 4" Paint Brush
- Air Compressor (optional)
- Hopper Gun (optional)
- Caulking Gun
- Caulking Knife
preparation
PLYWOOD
1. All plywood shall be a minimum of 5/8" thick, exterior grade, plugged and filled, finished side up.
2. Check all joints. All edges must be blocked and supported. Plywood shall be fastened with deck screws or ring shank nails in accordance with Local Building Codes.
3. Check for proper slope: ¼" per foot.
4. Check for any damage to the substrate, perimeter building materials and substrate joists and beams.
5. Plywood that requires additional slope or crickets may be done so using Excel-Crete and metal lath. Refer to Excel-Crete Data Sheet and Application Guide.
Note: If the plywood will be exposed to extended periods of weathering, it is recommended that the surface be initially treated with a coat of Excel-Coat #1. This will aid in preventing delamination, deterioration or warping.
NEW CONCRETE
1. Concrete shall be cured a minimum of 28 days prior to installation of the Excel-Coat system.
2. Curing shall be by means of water cure or dissipating compounds. Curing compounds shall be approved by an authorized representative of Excellent Coatings, Inc.
3. Check surface for excessive roughness, voids, protrusions or exposed aggregate. Poorly finished concrete will telegraph through the Excel-Coat finish.
4. Concrete moisture content shall not exceed 10%. Moisture Vapor Transmission shall not exceed 5 lbs. per square ft. per 24 hours.
5. All tooled and control joints shall be caulked with a urethane sealant. Structural cracks shall be routed, primed, and caulked with a two-part semi-rigid epoxy.
6. Concrete surfaces must be initially treated with Excel-Coat Primer 120 or PC-155 at a rate of 250 square feet per gallon prior to application of the Excel-Coat Pedestrian Membrane System.
Note: Do not apply over non-structural lightweight concrete without prior written approval.
OLD CONCRETE
1. Clean surface to remove all grease, oil, dust, powder or wax film with Prosoco 2010 All-Purpose Cleaner or detergent. Rinse and let dry.
2. Concrete with a hard slick surface must be etched with a solution of at least one part muriatic acid and three parts water or commercial concrete etch. Bead blasting is also an acceptable surface preparation. Rinse thoroughly with water and let dry.
3. Prime concrete with Primer 120 or PC-155 at the rate of 250 square feet per gallon.
Note: If the substrate holds water, proper drainage must be achieved. Install drains and scuppers where possible, and slope to drain (1/4" per foot) with Excel-Crete. See Excel-Crete Application Guide for mixing and installation instructions.
EXISTING SYSTEMS
Excel-Coat Waterproofing Systems can be installed over other waterproofing systems. Contact an Excel-Coat representative to find out what options are available for your particular application.
CRACK REPAIR
Minor / Hairline Cracks: Fill with Excel-Coat Patching Compound.
Medium Cracks (1/16" or greater): Route out and clean crack. Apply prime coat to crack. Use a two-part epoxy crack filler. Fill crack with epoxy; when cured, grind smooth.
Badly Damaged & Spalled Areas: Remove all loose, broken material. Prime area with Primer 120; fill with Excel-Crete Patching and Sloping Material. Smooth to a feather edge.
Uneven Surfaces Such as Exposed Aggregate or Salt Finished Concrete: Prime first then fill in and level with Excel-Crete Patching and Sloping Compound.
Above Grade Control Joints, & Expansion Joints: Do not bridge opening with fiberglass mat. Apply fiberglass mat and Excel-Coat #1 over expansion joint, slice fiberglass at the joint and let the fiberglass fall into the expansion joint. Using a 4” brush, push fiberglass edges down into the joint. Protect joint during texture and topcoat application. When system is complete, install urethane caulk.
METAL FLASHING
1. Metal flashing shall have a bonderized finish (etched and galvanized) and be a minimum 26 gauge.
2. It is recommended that a bed of caulk be placed on the plywood and the metal flashing seated into the caulk.
3. Metal flashing shall be fastened three inches on center in a W pattern with galvanized flashing nails. Flashing must be nailed down flat with no buckling.
4. All metal flashing must have a minimum 3" overlap at the connecting seams. Corners must be tight and the entire perimeter must be flashed. Overlaps shall be treated with a 4" strip of fiberglass saturated with one coat of Excel-Coat #1, or with deck seal tape saturated with Excel-Coat #1. Soldering of overlaps is also acceptable
All joints and seams must be caulked with a urethane sealant. Remove all excess sealant off of the plywood and flashing.
STAIR NOSING
Stair nosing is recommended on all stairs and landings to minimize wear. The stair nosing should be installed before the Excel-Coat membrane is installed. For proper drainage, the nosing should be 1"- 2 shorter than the step, and centered, allowing a gap on either side of nosing to allow water to drain off the stair.
application
EXCEL-COAT #1
PREPARATION:
1. With Excel-Coat Patching Compound, patch all joints, knotholes, cracks and other imperfections in the plywood as well as deck to metal seams of the flashing. Do not build up Patching Compound greater than 1/8". In areas requiring Sloping or fill greater than 1/8" use Excel-Crete. If building up a thickness greater than ½", it is recommended to reinforce Excel-Crete with 2.5 galvanized, expanded metal lath.
2. Excel-Coat hides only small imperfections, so care must be taken to assure the surface is completely clean, free from all dirt, oil, grease, old coatings and debris.
3. Should you decide to run the fiberglass up the vertical flashing or down the fascia, use a separate 4"-6" strip of fiberglass for the 90° turn. A strip of fiberglass is easier to work with and will mold/adhere better to the wall to deck interface. When this strip is cured, lay out the horizontal fiberglass and laminate as usual.
4. A bead of caulk can be used at the wall to deck interface to soften the angle.
APPLICATION:
To ensure proper adhesion, surface must be dust free and clean of debris, wax, dirt and oil.
1. Cover deck surface with fiberglass mat.
2. Butt the edges of the fiberglass together. Do not overlap.
3. Fiberglass should cover the edge of the flashing, terminating ½" from outside edge. If necessary, fiberglass may be turned up the metal flashing or down the fascia edge for extra protection.
4. With a 4" brush, generously apply material around the perimeter of the deck. It is essential that the material cover all the flashing at the walls and doorjambs.
5. Saturate the fiberglass mat with Excel-Coat #1.
6. Fiberglass should
be laminated into the mouths of all drains. Cut an X into wet
fiberglass at drain mouth; let fiberglass fall into drain.
Note: Do not cut in entire deck edge at one time. For best results, cut in 5'-6' at a time, making sure that you roll out the center immediately, always going wet into wet. This process will eliminate wrinkles in the fiberglass as you apply the Excel-Coat #1.
7. With a ¾" nap roller, apply Excel-Coat #1 at a rate of 50 square feet per gallon.
8. Laminate center of section by pouring approximately ½ gallon of Excel-Coat #1 on top of fiberglass.
9. Using moderate pressure, work puddle of Excel-Coat #1 into fiberglass mat, until thoroughly saturated. Excel-Coat #1 must penetrate through mat and into substrate.
10. Roll puddle towards you.
11. Before moving to the next section of the deck, go over the wet laminated area with a metal fiberglass roller to smooth out fibers, roll down bubbles and wrinkles, and bring a little resin to top of glass for pinhole free membrane.
12. Allow material to dry approximately 6-8 hours. Dry times may vary.
Hint: Be conscious of the amount of material you are using. Excel-Coat #1 is a low viscosity material, and it will have a tendency to run. Be generous with this material, and be sure to apply enough pressure on the roller to force the material through the fiberglass mat. However, be careful not to over roll.
Continually rolling back and forth will cause the fiberglass mat to stretch and break apart.
Tips & Tricks:
Do Not Dry Roll:
Dry rolling is dipping roller into pail and rolling out instead of pouring material onto deck. Resin will not penetrate fiberglass or bond to surface of deck. Dry rolling causes pinholes and air bubbles.
Bubbles:
While wet, if there is foreign matter under fiberglass causing a bubble, cut fiberglass open and remove it. Brush or roll the strands back down.
Wrinkles:
While wet, wrinkles can be repaired by using a utility knife and cutting directly across top of wrinkle, and brushing or rolling area back down.
These repairs should be done with the metal fiberglass roller.
DECK DRAINS & SCUPPERS:
Apply the entire Excel-Coat System around and into drain or scupper. Apply the system into drain or scupper at least ½" beyond joint. For proper drainage, drain, scupper, and grate should be lower than deck surface.
Do not use plastic drains or scuppers.
DETAILING FIBERGLASS:
After fiberglass mat has been laminated and allowed to dry, surface must be detailed before proceeding with texture application. Use Excel-Coat Patching Compound to patch seams, feather down edges of fiberglass and correct any other defects on laminated surface.
1. Hollow Spots and Bubbles: Suspect areas will usually have a large number of pinholes in the area of the bubble. Coating may even appear to be raised.
2. Small Bubbles: Bubbles no larger than a half a dollar can be cut out, patched and feathered out with two thin coats of Excel-Coat Patching Compound.
3. Large Bubbles: Large un-bonded areas should be completely removed and the fiberglass reapplied.
a. Lay a piece of fiberglass mat over area to be removed. The piece should be a little larger than what is being removed.
b. Double cut through both pieces of fiberglass mat.
c. Replace bad piece with new piece of fiberglass mat. It should fit perfectly.
d. Laminate patched in piece of fiberglass with paintbrush. Let dry.
e. Patch and feather repair with Excel-Coat Patching Compound.
4. Wrinkles: After Excel-Coat #1 has dried, wrinkles can be repaired by shaving down top of wrinkle until it is flush with deck’s surface. This can be achieved by using a 4" wide razor scraper. Fill in and feather with two thin coats of Excel-Coat Patching Compound.
5. Patching Seams: Fill gap between the two pieces of fiberglass by applying two thin coats of Excel-Coat Patching Compound with Bondo Spreader. Squeegee each coat on. Avoid creating a hump over seams.
6. Edges: On decks with flashing on the outer edges, fiberglass should stop 3/8 –1/2” back from outside edges. Feather all edges of fiberglass to edge of deck with Excel-Coat Patching Compound.
WATER TEST
1. It is recommended that once the Excel-Coat Pedestrian Traffic waterproof membrane has been installed that the deck be checked to ensure water slopes to drain.
2. Any additional fill or sloping that is necessary shall be done before the texture and top coats have been applied. Additional fill or sloping may be achieved using Excel Crete. See product Spec Data and Application Guide for guidelines and installation instructions.
EXCEL-COAT #200 (Texture)
PREPARATION:
1. Sweep in both directions or use a blower to clean the surface of any dirt or debris.
MIXING #200 TEXTURE:
1. Drill motor mix Excel-Coat #200 prior to applying to ensure color consistency.
APPLICATION OF # 200 TEXTURE (w/ HOPPER):
1. With tape and paper, mask off walls, railings, sliding doors, etc.
2. Set the air pressure on the compressor between 8-15 pounds per square inch (the higher the pressure, the finer the texture). Spray a little texture on a piece of cardboard or paper to check pattern of spray. Adjust gun and air pressure until you achieve desired pattern.
3. Starting with the perimeter of the deck, begin to apply texture coat at a rate of 75 square feet per gallon. Move the pattern pistol as evenly as possible to create a uniform spray and texture. Avoid spraying thick and thin spots.
4. Allow material to dry approximately 6-8 hours. Dry times may vary.
APPLICATION OF #200 (w/ ROLLER)
1. With a 4" brush, apply Excel-Coat #200 rollable grade around the perimeter of the deck and drains. It is essential that the material covers flashing at the wall and doorjambs, but it is not necessary to take it over the fascia edge.
2. With a ½" nap roller, apply Excel-Coat #200 at a rate of 75 square feet per gallon.
3. Pre-moisten roller cover with water. Spin out any excess water. This will help prevent roller cover from drawing moisture out of coating and will keep coating from clumping on roller.
4. Pour small amounts of Excel-Coat #200 onto deck surface and roll out.
5. To remove clumps of coating, move roller in a circular motion over clump, using moderate pressure.
6. Allow material to dry approximately 6-8 hours. Dry times may vary.
Hint: For a more uniform texture when rolling, spread the Excel-Coat #200 evenly over the deck surface, then back roll in the same direction.
Note: Because Excel-Coat #200 is thicker so it can be used with a hopper gun, it will be more difficult to achieve a uniform look when it is rolled. You may add some Excel-Coat #300 to the texture to make it easier to roll.
CAUTION:
When rolling Excel-Coat #200 on hot days or hot surfaces, material will begin to cure quickly. Apply the material then leave alone. “Touch ups” should be completed after the material has dried.
EXCEL-CRETE K/D & TINTED ADDITIVE
(Alternate Texture for Increased Skid Resistance and Durability)
MIXING OR EXCEL-CRETE K/D & TINTED ADDITIVE TEXTURE:
1. With a drill motor and a mixing attachment, mix 1 bag of Excel-Crete K/D (half bag at a time) with 1¼- 2 gallons of Excel-Crete Tinted Additive.
2. Continue mixing until both parts are thoroughly combined and a uniform consistency is achieved (approximately 3-4 minutes).
APPLICATION OF EXCEL-CRETE K/D & TINTED ADDITIVE (w/ HOPPER):
1. With tape and paper, mask off walls, railings, sliding doors, etc.2. Set the air pressure on the compressor between 6-15 pounds per square inch (the higher the pressure, the smaller the texture).
3. Starting with the perimeter of the deck, apply Excel-Crete K/D texture at a rate of 100-150 square feet per batch. Move the pattern pistol as evenly as possible to create a uniform spray and texture.
4. If a knock-down finish is desired, follow the texture application with a steel-finishing trowel. For best results, allow the texture to begin to dry (1-15 minutes) before knocking down.
5. Allow 24 hours to dry. Dry times may vary.
EXCEL-COAT #300 (Top Coat)
PREPARATION:
1. With a wallboard razor, lightly scrape off any irregularities in the texture.
2. Use a blower to clean the deck surface of any remaining dirt or debris.
APPLICATION:
1. With a 4" brush, apply Excel-Coat #300 around the perimeter of the deck and drains. The material should cover all flashing at the walls, doorjambs, and fascia edges.
2. Apply two thin coats of Excel-Coat #300 by roller or airless sprayer at the rate of 250 sq. ft. per gallon per coat, for a net yield of 125 sq. ft. per gallon total coverage.
3. Allow material 6-8 hours to dry. Dry times may vary.
4. Allow completed system to cure 24 hours before heavy foot traffic is permitted and an additional 72 hours before heavy objects are placed on the surface.
Note: Cold or inclement weather will effect the cure time of all Excel-Coat products. Do not install over wet substrate, in the rain or if the threat of rain exists within 24 hours.
DECORATIVE OPTIONS
EXCEL-COAT TWO-TONE FINISH
This finish is achieved by first rolling Excel-Coat #300 over the fiberglass reinforced membrane and then using a hopper gun to “shoot” two different colors of texture. The texture material can be Excel-Coat #200, which is an acrylic base with fibrous aggregate, or you can use white Excel-Crete K/D with Tinted Additive to your desired colors and sprayed over the deck. The system is completed with two coats of an Excel-Coat clear sealer.
EXCEL-COAT BC-100 SYSTEM
The Excel-Coat BC-100 System is a colored quartz aggregate system that is broadcast into an acrylic matrix. This topping is suitable finish when applying the Pedestrian Traffic membrane over concrete or over the Excel-Coat Fire System over plywood substrates. See Excel-Coat BC-100 System Spec Data Sheet and Application Guide for instructions.
EXCEL-COAT K/D & K/D II SYSTEMS
The Excel-Coat K/D & K/D II Systems are polymerized cement products that can be used to create durable, attractive patterns and textures.
The Excel-Coat K/D & K/D II decorative patterns may be used in conjunction with the Excel-Coat Pedestrian Traffic Membrane (over concrete) or the Fire System (over plywood). See Excel-Coat K/D & K/D II Systems Spec Data and appropriate Application Guides for application instructions.
Note: To apply a K/D or K/D II decorative pattern or stamped finish over plywood, the Excel-Coat Fire System must be installed first.
Note: To insure uniformity of color, drill-mix all materials before using.
1/04
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