For Epoxy Coating & Epoxy Self-Leveling Systems 1. 🎯 Objective of the Training
Equip installation crew with the knowledge, skills, and safety awareness required to correctly install epoxy-based flooring systems on-site, ensuring quality, durability, and compliance with manufacturer and project specifications. 2. 📋 Training Scope
This training covers:

• Jobsite preparation & safety
• Surface preparation
• Material handling & mixing
• Tools and application techniques
• Troubleshooting and quality checks
• Cleaning and maintenance
• Final handover procedures

3. 👷 Roles and Responsibilities

Role	Responsibility
Team Leader / Supervisor	Coordination, quality control, schedule monitoring
Surface Prep Team	Mechanical preparation, vacuuming, crack repairs
Mixing Operator	Material mixing, ratio control, pot life monitoring
Applicators	Apply primer, coating, or SL system as per spec
Safety Officer	PPE enforcement, ventilation, spill response

4. 🧰 Tools & Equipment Overview

Tool	Use
Diamond grinder / Shot blaster	Surface preparation
Industrial vacuum	Dust removal
Mixing drill with paddle	Resin + hardener mixing
Notched trowel / Gauge rake	Self-leveling application
Short nap rollers	Primer & coating application
Spike roller	Deaeration (for SL)
Spiked shoes	Movement on wet epoxy
PPE: gloves, respirator, goggles	Health & safety

5. 🛠️ Step-by-Step Work Instruction
🔹 5.1 Surface Preparation (For Both Systems)

1. Mark work zones and isolate traffic
2. Grind or blast concrete to remove laitance, old coatings, oil, etc.
3. Repair cracks or holes with epoxy mortar
4. Vacuum thoroughly
5. Moisture check: Use moisture meter (must be <4%)

🔹 5.2 Material Handling and Mixing

Step	Guidelines
Check TDS	Always refer to manufacturer's mixing ratio and pot life
Use clean containers	Avoid contamination
Mix Part A (resin) and Part B (hardener)	Use slow-speed drill paddle
Mix for at least 2–3 minutes	Scrape sides and bottom thoroughly
For SL: Add filler slowly	Continue mixing until lump-free

⚠️ Important: Always apply mixed material within its pot life (usually 20–40 minutes depending on temperature). 🔹 5.3 Application Techniques
Epoxy Coating System (Roll Applied):

Step	Description
Primer	Apply using roller. Wait for full cure (check tackiness).
Main Coat	Roller or squeegee apply, then backroll for uniformity.
Optional Topcoat	PU or epoxy clear/top layer if needed for UV or chemical resistance.

Epoxy Self-Leveling System (Trowel Applied):

Step	Description
Primer	Apply and allow to cure (may broadcast sand if required).
Scratch coat (if surface uneven)	Use flat trowel to cover imperfections.
Self-Leveling	Pour and spread with notched trowel or rake.
Spike Roll	Immediately roll to remove bubbles (within 10 mins).
Optional Topcoat	Applied after full cure of SL layer.

6. ✅ Quality Control Checks

Checkpoint	Method
Surface profile (CSP)	Visual comparator
Ambient temperature/humidity	Thermo-hygrometer
Wet film thickness	Gauge check during application
Dry film thickness	Use Elcometer (DFT) after cure
Adhesion	Pull-off test (ASTM D4541)
Finish quality	Visual inspection for bubbles, roller marks, levelness

7. ❌ Common Installation Mistakes & How to Avoid

Mistake	Prevention
Uneven finish / ridges	Use proper trowel angle and re-roll before gel time
Blistering	Avoid applying on damp surfaces
Delamination	Ensure surface prep and primer bonding are sound
Early foot traffic	Respect curing time — barrier the area
Mixing ratio errors	Use calibrated buckets or scale

8. 🧯 Health & Safety

• Wear gloves, goggles, and organic vapor respirators at all times.
• Maintain good ventilation (fans or air movers).
• Have spill kits and fire extinguishers nearby.
• Do not eat or smoke near materials.
• Dispose of waste and cleaning rags in metal bins.
• Wash hands and exposed skin thoroughly after work.

9. 🧼 Cleaning After Installation

• Tools must be cleaned with solvent or water (as per resin type) before the epoxy cures.
• Used containers should be properly disposed of (not in public drains).
• Leftover mixed epoxy must be allowed to harden before disposal.

10. 📦 Final Handover & Maintenance Advice

• Allow full cure before handing over: 5–7 days typical.
• Clean floors with pH-neutral cleaners only.
• Avoid dragging sharp objects or dragging heavy pallets.
• Recoat timeline: within recoat window (as per TDS) or surface sanding will be needed.

11. 📅 Suggested Training Duration

Topic	Time
Surface Prep	30 min
Mixing & Application	1 hour
QC & Troubleshooting	30 min
Safety	30 min
Tool Demo (Hands-On)	1–2 hours