Aquafin water vaporproofing

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What Lurks Under Your Floor?
ICRI 2010 SPRING CONVENTION Thursday April 15th
2010
Presented By Brian Cordak
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MOISTURE VAPOR EMISSION
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• Understanding The Challenge
• Moisture Activity In Concrete

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Moisture Activity In Concrete CAN BE ENCOUNTERED
EITHER IN

• In Liquid Form
• Capillary Action
• Hydrostatic Pressure
• Measured in psi.
• OR

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Moisture Vapor TransmissionA COMMON OCCURANCE IN
THE FLOORING INDUSTRY

• In Gas Form
• Diffusion Action
• Vapor Static Pressure
• Measured in lb/1000 ft2/24 hr.
• (MVER)

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Failure of a Water Based VCT Adhesive Due to
Moisture Vapor Emission
Photo courtesy of Construction Technology
Laboratories, Inc."
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Failure of a Polyurethane Adhesive Due
toMoisture Vapor Emission
Example running track
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Failure of a Polyurethane Adhesive Due
toMoisture Vapor Emission
Before
After
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Failure of an Epoxy Mortar Overlay Due To
Moisture Vapor Emission
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Failure of Trowel Down Epoxy Coating Due
toMoisture Vapor Emission
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Failure of Thin Film Epoxy Coating Due
toMoisture Vapor Emission
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All Result In Lost
The Common Denominators?
Probably Could Have Been Avoided!!
Increased Liability
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WHEREVAPOR EMISSION PROBLEMS APPEAR

• SLABS ON GRADE
• SLABS ABOVE GRADE
• SLABS BELOW GRADE

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GENERALLY SPEAKINGVAPOR EMMISSION PROBLEMSCAN
BE CATAGORIZED IN ONE OF TWO WAYS

• 1. Concrete Drying Issues
• Closed Slab or Above Grade Situations
• 2. Chronic Diffusion Issues
• Open Slab Situations

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A Closed Slab System is where an PERMANENT VAPOR
BARRIER or non-perforated metal decking is in
place directly beneath the concrete. In a Closed
Slab System the only source of moisture is
free-water originating from within the concrete
itself.
CLOSED SLAB SYSTEM
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OPEN SLAB SYSTEM
An Open Slab System is the most challenging
condition for a topical moisture pH suppression
system as moisture within the concrete will
typically rise above the originally tested levels
over time.
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SOME COMMON CAUSES OFVAPOR EMMISSION PROBLEMS

• OLDER BUILDING Without Any Under Slab Vapor
  Barrier
• OLDER BUILDING With a Damaged or Deteriorated
  Under Slab Vapor Barrier

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COMMONLY OVERLOOKED SITUATIONS LEADING
TOPOTENTIAL VAPOR MOISTURE TRANSMISSION PROBLEMS

• Renovation Or Reconfiguration Of Existing Space
• NEW CONSTRUCTION With A Compromised (Direct
  Contact) V.B.
• or
• Fill Saturated Before Slab Pour
• (Indirect Contact)

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GENERALLY IGNORED SITUATIONS LEADING TOPOTENTIAL
VAPOR MOISTURE TRANSMISSION PROBLEMS

• Renovation Or Reconfiguration Of Existing Space
• NEW CONSTRUCTION With Compromised (Direct
  Contact) V.B.
• Fill Saturated Before Slab Pour
• (Indirect Contact) V.B.
• FAST TRACK/NEW PROJECT
• No Time to Wait for Concrete to Fully Dry

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Reasons Achieving Proper MVER in New Construction
Can Be Difficult
1. Concrete Or Fill Moisture Events

• 2. WATER Of Convenience In The Fresh Concrete Mix

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Amount Of WATER In Fresh Concrete

• Example A simple 6-sack concrete mix consists of
• 564 lb cement/yd3 (Type I, II, ..)
• 3,200 lb aggregates/yd3
• Water for mixing, placing hydration of cement
• Additives (superplasticizer, air entrainment,
  etc.)
• W/C (water/cement ratio) 0.5 assumed
• Typical Amount of WATER 0.5 x 564 lb 282 lb
• 34 gal/yd3

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• Total WATER in concrete
• mix 34 gal/yd3
• b. REQUIRED
• WATER for hydration of cement 35 12
  gal/yd3
• c. RESULT
• 65 surplus WATER needs
• to evaporate 22 gal/yd3

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How Long Until Concrete Is Dry?Blow 75
RH(Actually Under 3 to 5 lbs of MVER)

• Rule Of Thumb For Concrete Drying Time
• ONE MONTH PER 1 OF SLAB THICKNESS (Typically
  Will More Than Double In Winter)
• Lightweight Concrete Mix Designs Dry At A Rate 2
  Times (or more) Than Normal Concrete
• ALWAYS TEST TO BE SURE!!!

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How Is Moisture Vapor Emission Measured?
ASTM F 1869 3 Test Kits For The First 1000 S/F of
Floor 1 Additional Test Kit For Each Additional
1000 S/F Example 7000 S/F 9 Total Test Kits
Calcium Chloride Test Kit
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Insufficient Number of Calcium Chloride Tests
X
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How Is Moisture Vapor Emission Measured?
Another New Test Method Is Currently Being
Used ASTM F 2170 Test Method For Determining
Relative Humidity In Concrete Floor Slabs Using
In-Situ Probes
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WHERECAN VAPOR EMISSION PROBLEMS APPEAR?

• SLABS ON GRADE

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SLABS ON GRADE
Outdoors
Indoors
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SLABS ON GRADE
Outdoors
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WHERECAN VAPOR EMISSION PROBLEMS APPEAR?

• SLABS ON GRADE
• SLABS ABOVE GRADE

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SLABS ABOVE GRADE
Structural Concrete Components
Concrete on Non-Vented Metal Deck
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WHERECAN VAPOR EMISSION PROBLEMS APPEAR?

• SLABS ON GRADE
• SLABS ABOVE GRADE
• SLABS BELOW GRADE

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SLABS BELOW GRADE
Basements
Tunnels
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Rehabilitation Or Remedial Projects
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HOWDOES VAPOR EMISSION CAUSE FLOORING SYSTEMS TO
FAIL?
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Moisture Movement Through Interior Slabs On
Grade
VAPOR EMISSION Varies Throughout The Slab Itself
May Also Fluctuate During Different Times Of
Year
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Moisture Vapor Emission TRANSPORTS MINERALS
CONDENSATES AT SURFACE
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SOLUBLE METAL IONS

• Calcium Hydroxide Free Lime
• Potassium Hydroxide Caustic
• Sodium Hydroxide Unstable
• Result Dissolved metal ions raise the pH levels
  in the solution allowing a chemical attack on
  the organic compounds.

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pH Scale is Logarithmic

• pH 7 is Neutral
• pH 7 and Lower is Acid
• pH 7 and Higher is Alkaline
• pH 7 ---to--- pH 14 is 10 MILLION
• Adhesive Warranty pH 8.2 to 9

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Moisture Vapor Emission ASR
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How Should One Proceed When MVER Is Not Within
The Required 3 or 5 lbs/24 hr1000 ft2 or Below
75 RH

• Risk Installing the Floor System?
• Pretend It Is Not A Problem?
• Run Away Hide?
• NO!

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• Install A Quality
• Negative Side or Surface Applied
• VAPOR SUPPRESSANT

Vapor Suppressant
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Various Vapor Suppression SystemsCurrently
there are 6 major system categories or material
approaches being marketed tomitigate a high
moisture or pH condition in concrete sub-floors.
Treatments rangefrom single coat applications to
multi-stage systems that combine two or
morecategories of materials.1. Reactive
PenetrantsReactive penetrants are fluid applied
treatments designed to penetrate the
concretesurface and react chemically with the
concrete. The goal of such treatments is
toreduce the moisture vapor emission rate (MVER)
and to bind up soluble alkali suchthat high pH
levels are not experienced at the
concrete/adhesive interface.The most common
reactive formulations used for moisture pH
suppression arebased on sodium silicate,
potassium silicate or lithium silicate.Before
giving consideration to a silicate-based,
reactive penetrant one must havethorough
knowledge of the concrete composition and degree
of surface carbonation.Concrete mixtures that
contain pozzolanic materials such as Fly Ash or
Slag canreduce available reactive material
within the concrete and thus lead to
incompletereaction of the silicate-based
treatment. Concrete that is more than
superficiallycarbonated may produce a similar
result. Not only will un-reacted silicates
notachieve the desired reduction in the moisture
vapor emission rate (MVER) but theycan inhibit
the bond of subsequent flooring or coating
applications.Reactive penetrants, as a stand
alone treatment, are considered a very high
riskapproach to topical moisture and pH
suppression.2. Cementitious DensificationModifi
ed cementitious overlays are intended to isolate
the concrete surface fromadhesives or coatings
applied above. Such systems are intended to lower
moisturetransfer and restrict soluble alkalis
within the concrete sub-floor from reaching
theadhesive/overlay interface but can be
inconsistent in efficacy.
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Various Vapor Suppression Systems 3.
SealersFluid applied sealers are available to
help reduce moisture transfer and isolate
theconcrete from the adhesive applied above.
Most sealers have warranty limits between 8 12
lbs or less and low ph stability. Therefore
sealers should be limited for closed slab systems
where the demands and required performance is
limited.4. Specialty CoatingsHybrid
epoxy-based or epoxy-modified coatings,
specifically designed for highmoisture/pH
conditions, reduce the Moisture Vapor Emission
Rate (MVER) and actas an isolation barrier to
keep solutions of highly alkaline salts within
the concretefrom reaching the subsequently
applied adhesive or coating.One, two and three
coat systems are available. Some systems may
require multiple coats to achieve sufficient mil
thickness on very aggressively shot blasted
concrete.Additional leveling or cementitious
substrate material may be required over
thecoating. When that becomes necessary the
materials and processes to follow should be
approved by the manufacturer of the suppressant
system.5. Dispersement MembranesDispersement
membranes were historically one of the first
approaches to topicalmoisture suppression that
experienced a reasonable measure of success.
Suchsystems utilize a special fabric adhered to
the surface of the concrete whichprovides a
lateral avenue for water vapor to diffuse. These
membranes are only for floating systems. 6.
Combination SystemsSeveral companies utilize a
combination or Cocktail approach where two or
moreof the systems discussed above are combined,
but this approach is usually cost prohibitive
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DEFICIENCIES OF INFERIOR SURFACE APPLIED VAPOR
SUPPRESSANTS

• MANY VAPOR SUPPRESSANTS CAN ONLY PROTECT UP TO 8,
  10 or 12 LBS MVER (NOT FOR OPEN SYSTEMS)
• FEW VAPOR SUPPRESSANTS CAN WITHSTAND 25 LBS OF
  MVER
• STILL LESS ARE 1-COAT SYSTEMS! 2-COAT 3-COAT
  SYSTEMS ARE AVAILABLE.BUT WHY?!?
• BEWARE!!! MANY DO NOT PERFORM IN HIGH ph
  ENVIRONMENTS OF 13 TO 14
• HAVE MOISTURE SENSITIVE CHARACTERISTICS

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Desired Capabilities Of Quality Surface Applied
Vapor Suppressants

• Must Have Ability To Be Applied To Fresh or Old
  Concrete
• Must Withstand Constant pH 13 14 (Normal pH of
  fresh concrete is 12 13) (Aged concrete
  has a pH 8 10)
• Must Provide Proper pH On Surface For Flooring
  Applications (Neutral 7)
• Must Tolerate High or Unknown MVER
• Moisture Insensitive Formulation (Damp Surfaces
  OK!)

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Must Be Compatible With Most Flooring Materials

• Cementitious Underlayment
• Colored quartz
• Carpet
• Epoxy
• Epoxy terrazzo
• Linoleum
• Polyurea
• Synthetic/rubber
• VCT
• Wood

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APPLYA QUALITY SURFACE APPLIED VAPOR SUPPRESANT
WHEN

• MVER (Moisture Vapor Emission Rate)
• isGreater Than 3 or 5 lb/24 hr1000 SF
• (as per floor covering manufacturer)
• IF ONE IGNORES HIGH MVER YOU WILL LIKELY SUFFER
  COSTLY FAILURES REPAIRS

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HOW MOISTURE RETARDING EPOXY COATINGS WORK
Vapor Suppressant
Vapor Suppressant
V. B.
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Topically Applied Vapor Barrier Installation
CHAPTER II
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STEPS TO SUCCESSFULVAPOR SUPPRESSANTINSTALLATION
S
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ALWAYSEvaluate Diagnose Existing Floor
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TEST FOR SUCCESS

• Extract Core Samples From Both.. Affected
  Unaffected Areas
• Analyze Cores In Lab Under Scanning Electron
  Microscope (SEM)
• Analyze Cores Using Ion Chromatography
• Analyze Cores Using Infra Red Spectro Photometer

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Example of Test Cores
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Example 1 Core Analysis
40x magnification of top layer of core
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Sample Core Analysis The Culprit!
Organic matter
Picture 12.5x magnification
Organic Matter Prevented Penetration Adhesion
of Vapor Suppressant
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Sample Core Analysis
Flooring System
Vapor Suppressant
Picture 20x magnification

• Flooring System Bonds Well to Vapor Suppressant
• Vapor Suppressant Did NOT Bond To Substrate

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Example 1 Thermo Analysis of Core Sample
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Example 1 Thermo Analysis Interpretation
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Example 2 IR Spectro Photometer Analysis
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Example of Ion Chromatography Test Results

Sample Identification Core 1 Core 1 Core 2 Core 2
Sample Depth (mm - BTC) 0-3 mm 3-5 mm 0-3 mm 3-5 mm

IONIC CONSTITUENT CONCENTRATION (ppm) CONCENTRATION (ppm) CONCENTRATION (ppm) CONCENTRATION (ppm)

Sodium (Na) 1410 1090 1160 1140

Potassium (K) 3500 2610 1080 1050

Sulfate (SO4) 2940 4690 3770 2690

Chloride (Cl) 180 110 40 40
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• Example of Infrared Spectroscopy Test Results
• Core 1 (MI28014-01C) 0-3 mm BTC The amount of
  organic extractable residue comprises
  approximately 11,100 ppm (1.110) of the concrete
  mass. The IR spectrum of the residue indicates
  the presence of alkyd and polyester resin
  material.
• Core 1 (MI28014-01A) 3-5 mm BTC The amount of
  organic extractable residue comprises
  approximately 8940 ppm (0.894) of the concrete
  mass. The IR spectrum of the residue indicates
  the presence of alkyd and polyester resin
  material.
• Core 2 (MI28014-02A) 0-3 mm BTC The amount of
  organic extractable residue comprises
  approximately 16800 ppm (1.680) of the concrete
  mass. The IR spectrum of the residue indicates
  the presence of alkyd and polyester resin
  material.
• Core 2 (MI28014-02C) 3-5 mm BTC The amount of
  organic extractable residue comprises
  approximately 9,390 ppm (0.939) of the concrete
  mass. The IR spectrum of the residue indicates
  the presence of alkyd and polyester resin
  material
• . Note ''BTC' Below the Top surface of the
  Core

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Epoxy Vapor Suppressant Penetration
Vapor Suppressant Thickness
Vapor Suppressant Penetration
Microscopy Showing Penetration Of The Vapor
Suppressant
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CROSS SECTION OF AN EPOXY FLOORING SYSTEM
Epoxy Flooring
Sand Broadcast
Vapor Suppressant
Vapor Suppressant Penetration
Microscopy Of A Concrete Core
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CONDENSATION ISSUES
Another Benefit of Using A Moisture Insensitive
Suppressant
Generally floor coverings and adhesives should
not be installed any time the air temperature or
concrete surface temperature is within 5 degrees
F above the dew point. This also applies to most
surface applied vapor barriers? NOT If
Suppressant Is Moisture Tolerant!!
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DEW POINT TEMPERATURE
N/A
At the DEW POINT TEMPERATURE moisture contained
in air begins to condense onto surrounding
surfaces.
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EXAMPLE OF CONDENSATION
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EXAMPLE OF CONDENSATION
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CARBONATION

• CO2 (present in air) REACTS WITH HYDRATED CEMENT
  WHEN MOISTURE IS PRESENT, AND LOWERS THE pH OF
  THE HARDENED PORTLAND CEMENT PASTE TO 8.3
• THE LOWER pH NO LONGER PROTECTS THE REINFORCEMENT
  FROM CORROSION
• CARBONATION ALSO DENSIFIES THE AFFECTED AREAS,
  PREVENTING SOME VAPOR BARRIERS FROM BONDING

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• Close-Up of Delaminating System

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CROSS SECTION OF A PROPERLY INSTALLED EPOXY
FLOORING SYSTEM
Epoxy flooring
Sand broadcast
Vapor Suppressant
Vapor Suppressant Penetration

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Surface Preparation!

• ACID ETCHING?
• ABSOLUTELY NOT!!!

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Proper Surface Preparation

• Steel Shotblasting

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Proper Surface Preparation

• Grinding

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Proper Surface Preparation

• Scarifying

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Concrete Surface Profiles
CSP- 2
CSP- 3
CSP- 4
X
CSP- 5
CSP- 6
CSP- 7
CSP- 8
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Degrease If Needed!

• Remove All Contaminants

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Proper Surface Preparation

• Remove All Contaminants

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Proper Surface Preparation

• Remove Excess Water Puddles

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Completely Mix Vapor Suppressant Material
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• Mix Thoroughly Spread Suppressant at Prescribed
  Rate

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• Back Roll To Assure A Uniform System Mil Thickness

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Call On Your Local
Professionals
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Application Step 1

• Apply Vapor Suppressant with 3/8 Nap Roller or
  Notched Squeegee

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Application Step 2

• Scrub Vapor Suppressant Into Substrate Using
  Stiff Bristle Broom

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Application Step 3

• Re-Roll Vapor Suppressant Material To Insure
  Uniform Mil Thickness

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Typical Installation Procedure

• Back Roll Suppressant Assuring Uniform Mil
  Thickness

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Application Step 4

• Broadcast Quartz Sand (if required) Subsequent
  Installation Bond/Compatibility

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Broadcast Quartz Sand to Complete Rejection (full
broadcast)
Application Step 4
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Completed Sand Broadcast Suppressant
Application
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Successful Installation of Flooring System over
AQUAFIN SG-2
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Suppressant Non-Broadcast System

• Texas AM 75,000 s/f Project

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Typical Installation Procedure

• Mix Thoroughly Spread Suppressant at Prescribed
  Rate

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TYPICAL Installation Procedure

• Scrub/Massage Suppressant Into Substrate

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• Completed Non- Broadcast Installation

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• Outdoor Application Over Vapor Suppressant System

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Keys to Successful
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• Why AQUAFIN For
• Moisture Suppressant Systems??
• Quality Products
• Better Installation Safeguards
• Simplified Systems
• Technically Adept
• Professional Integrity
• We Understand Work Within Our Limitations
• Alliance with Professional Installers

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THANK YOU!
QUESTIONS?