Just about ready, but have questions...

[Reflex]

Good day,

After lurking here for quite some time and being most impressed with the exchange of information, I decided to register and take a stab at a post. It's been very educational and a true pleasure to read your posts over the last few months.

I've just finished a 42 x 12 x 56 poll barn and have researched floor finishes and methods until I've just about got myself chasing my tail. I'd enjoy and value your opinions. Here's the scoop:

Floor:
Floor poured April 3, 2015
2207 square feet
5" Thick
10 Mil vapor barrier
2" 25 psi R-10 foam on top of vapor barrier
Radiant tubing in floor
Finish is smooth to slick
Ran a calcium chloride test at 30 days at got an average of 6.02 lbs. per 1000
Dehumidifier and fan have been running now for 8 days
Building is sealed, painted, and insulated
No stains or spills, have kept anything with oil or grease in it out of the building.

Decisions:
Epoxy or urethane or both?
Dimabrush or Diamond grinder (having trouble finding dust shroud)?
Flakes, grit, or smooth (interested in utility)?

Questions:
If I use epoxy, how long do I have to get it down (pot life)?
Pot life (epoxy) - how do I get the whole thing down in 30 - 50 minutes? Am Am I allowed to keep a wet edge and keep spreading?
How many people should I have to help?
How much to mix at one time?
How many coats (primer, epoxy, 2 urethane)?
I have a few blisters in the floor, prep, patch/fix, sand again?
Any idea how long it might take my slab to get to 3lbs per 1000 at 40% humidity and 65 degrees?

Leaning toward:
Legacy Industrial - Primer, SD Epoxy, two coats HD322 urethane

Purpose of building:
Aircraft assembly in half, work shop, tractor storage, etc. in other half.

Thoughts and suggestions?

Pics of barn below.

Thanks in advance for your comments/advice.

Reflex

 

[James-W]

Welcome to the site. Great looking building! What type of work are you planning on doing in it?

 

[LegacyIndustrial]

Epoxy under urethane as you mentioned.
Diamabrush
No flakes for utility, go light gray or white.
You have approx 30 minutes for each 1.5 gal batch of epoxy , yes we even send you 1.5 gal units with a 3 gal purchase. More than enough time to apply.
Urethane has a very long pot-life. Mix, pour out and roll, you will see this is not difficult.

At least one extra set of hands is great.

Again, 1.5 gal batches, as packaged.
Coat 1 Standard Primer
Coat 2 SD Epoxy
Coat 3 HD 322 hp urethane, same color as the epoxy
Coat 4 same-but optional.

It should be ok after 30 days of cure. If you are still worried about moisture apply a moisture vapor barrier like our Aqua-Dike.

Yes, repair any defects.

This is an excellent system for your application and naturally we support your endeavor all the way through, even on holiday weekends.

Here are some pics from a similar GJ member's project:





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[Shea]

Keep one wet edge going all the way across from left to right. One person can roll while the other can mix and cut in. Ideally the person mixing will finish about the same time the previous batch is finished being rolled. Do that and it will go like clock work.

 

[Reflex]

Gentlemen,

Thanks for the suggestions and kind words. I'm headed out in a few minutes to see if a Home Depot in my area actually has a Diamabrush prep tool and a dust shroud to go on the machine. If so, I'll pick it up and get to work!

Will probably give Legacy a call in the next couple of days to order the coating as well as some tools.

Received several PM's regarding the barn/shop, here are the highlights:

Built by Morton
42 x 12 x 56
Fully insulated (Manual J = 37, 512 BTU/h heat loss at 65 delta)
5" slab
26 gauge steel walls and roof
32' door
Pitch is 5/12
200 amp service
3 50 amp 220v outlets
120v outlets every 10'
32 4' lights (81 foot candles per sq ft)
Inside Upper is perforated acoustical steel
Inside Lower is wood siding.
Insulation is R-19 walls, R-50 ceiling, R-10 under slab
Radiant flooring
Has plumbing
Floor drains = 2 @ 4' each
A/C to be installed after floor is complete

Purpose: Aircraft assembly

FYI - I couldn't be happier with Morton, although the shop is new. Ask me again in 10 years

Again, thanks to everybody for the input.

Reflex

 

[Gotcha640]

I assume you keep the door closed during coating to keep bugs and dust out, and you said you haven't got the AC in yet. Do you have a plan for ventilation so you don't pass out? Great big screen?

 

[LegacyIndustrial]

It's always a good idea to have a well ventilated space when working with coatings.
However, the only portion of this that requires a respirator is the HD322. The balance can be applied without, low smell, low or no VOC.

Coat and close down the doors/windows once you are finished to keep the critters out.

 

[LegacyIndustrial]

Reflex: Glad to be a part of this project. Please keep us posted with your progress!


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[mnavillus]

From what I'm reading you have all you ducks in a row....good luck with the prep work!

Great use of the forum!