Epoxyshield help

[Microfiche]

We just finished coating my basement floor with gloss grey Epoxyshield bought from Home Depot last week and it worked very well.
That 2.5 garage kit had 4 cans of material.

They ran out, so we bought another 2 of the 7.1 liter kits (2.5 car garage) from Canadian Tire. These kits had the bags instead of cans.
We just did my first 500 square feet in the garage with the first bag kit and ran into an issue.
I kneaded the part A and part B sides for a few minutes, then rolled the A side into the B side and mixed in the bag for at least 3 minutes.
I could not feel any of the thicker activator (almost felt paste-like?) left on the part B side of the bag at that point, and the coating felt uniformly liquid.
Let it sit for about 12 minutes (between 16 – 18° C in the garage – the air was 18°, and the concrete was 16° C.
Poured the mixture into the tray and started rolling, but immediately noticed “lumps” in the mixture.
I didn’t have time to take pictures at that point unfortunately – but some of the lumps might have been dime sized?
If you applied a LOT of pressure with the roller or a brush, you could smooth these “lumps” out, but it was a lot of extra work.

However, now that it is curing, I can see that the lumps (though much smaller) have returned in some areas?
See attached pictures.

This is NOT debris from the floor – the floor was completely vacuumed before we started. We did a LOT of floor prep.
These lumps were in the paint tray.
Is there a problem with this kit? Is the activator in the bag versions a LOT thicker than in the can versions? As I said, it almost feels like a paste in the bag. I have emailed Rustoleum, but last time I messaged them it took about 10 days for a reply.

 

[Shea]

Don't email Rust-Oleum. Instead, call them for much quicker service. Once that cures, you will need to sand it out and recoat the floor again. Rust-Oleum customer service is usually pretty good at sending out new product for issues like this.

Did you save the box? They may ask for the bar codes on the side to determine how old it was.

 

[Microfiche]

Don't email Rust-Oleum. Instead, call them for much quicker service. Once that cures, you will need to sand it out and recoat the floor again. Rust-Oleum customer service is usually pretty good at sending out new product for issues like this.

Did you save the box? They may ask for the bar codes on the side to determine how old it was.

Thanks @Shea,

I email because my hearing is impaired, and I often can't understand the people staffing the "support" lines - especially if there are heavy foreign accents. I will try calling them tomorrow.
I would like to know from anyone who has used these kits with the "burst pack" if the consistency of the part b activator was more of a paste than a liquid. I opened up my second kit and the part B activator was like plasticine as well in both bags. Seems strange to me as the canned activator was more like warm honey.

 

[Shea]

No, the activator should not be like that. It should have a consistency a little less viscous than honey.

 

[Microfiche]

Ended up cutting open the burst pouches to mix in a pail so I could see what was happening. Pics attached (screenshots from videos I can't post yet)
Went back to store where I bought and they refunded me for both kits, I went and opened the other two kits they had in stock and they seemed to be the same - crystallized activator. Drove 50 km to the next closest store that stocked the stuff and they had 1 kit - with cans. Product seems perfect in the cans.
The problem areas are still tacky 4 days later, sanding the bumps down reveals gooey coating inside. Rustoleum suggested wiping off with acetone and mineral spirits, but that doesn't seem to remove the product. I am REALLY hoping that applying good product over this is not going to compound my problems. Rustoleum "assured" me that this will work.

 

[Shea]

You are not the first to have these problems. Rust-Oleum deals with these issues all the time and has to correct for it. That is why I was fairly certain you would be supplied with free replacement in one way or another. Just follow their instructions in case you have more problems.

 

[landon3]

Ended up cutting open the burst pouches to mix in a pail so I could see what was happening. Pics attached (screenshots from videos I can't post yet)
Went back to store where I bought and they refunded me for both kits, I went and opened the other two kits they had in stock and they seemed to be the same - crystallized activator. Drove 50 km to the next closest store that stocked the stuff and they had 1 kit - with cans. Product seems perfect in the cans.
The problem areas are still tacky 4 days later, sanding the bumps down reveals gooey coating inside. Rustoleum suggested wiping off with acetone and mineral spirits, but that doesn't seem to remove the product. I am REALLY hoping that applying good product over this is not going to compound my problems. Rustoleum "assured" me that this will work.

Not sure if you’ll see this, but I’m in the same boat now. Rustoleum told me that this is not common and that they’ve never heard of this issue before, I knew it was BS, so I started searching google for help.

Did your attempt to epoxy over the sanded area help? I’m not sure what to do, half the garage has these gooey lumps that sanding will just spread around.

 

[Armorpoxy]

Definitely looks like some off spec material. Agree Rustoleum does offer decent support and you should try best way to contact them for replacement material and to recoat.