EPDM Floor Construction Solution

EPDM Floor Construction Solution

1. Construction Steps

    Ground Cleanup 

    Substrate Treatment 

    Construction Preparation

    EPDM Layer Paving 

    Detail Repairing 

    Positioning

    Line Marking 

     Project Delivery

2. Construction Process

(1) Site Cleanup and Repair

To ensure the quality of the EPDM surface layer, the base surface must be thoroughly cleaned to fully utilize the adhesion of the polyurethane.

①Oil stains: Remove with cleaning agent; areas heavily contaminated with engine oil need to be excavated and re-built.

② Soil and dust: Sweep it clean with a broom;

③ Firmly attached protrusions: remove and clean them with a scraper;

④ Concrete layer wheel tracks: Flatten with a hammer;

⑤ Soil: Wash with a high-pressure water jet;

⑥ Clutter in the surrounding area: Large trees or deciduous plants need to be shaken gently to accelerate leaf shedding and removed in advance, and the surrounding area should be kept as free of wind to blow away the clutter as possible;

⑦ Close off the construction site and minimize the entry and exit of vehicles and pedestrians.

(2) Substrate Review

   ① The foundation of the court should be free of obvious cracks, with a uniform and firm surface, no pitting, smooth and even joints, clear edge lines and corners, and no defects.

② There is no obvious water accumulation or wave phenomenon after watering or heavy rain.

③ The basic maintenance period should be at least 4 weeks.

(3) Preparation for EPDM layer construction

① Construction work site layout preparation

a) Determine the locations of water and power supplies, connect them according to specifications, and ensure safety;

b) Determine the material entry and exit channels and stacking areas;

c) Determine the work surface for EPDM materials. The surface should be flat and firm, and measures should be taken to prevent contamination.

 ② Preparation of construction tools: Check the performance of tools and mixing and transportation machinery. Test the machines once and operate them according to the actual conditions of the project. In accordance with the principle of optimization, minimize the material transportation distance and determine the order of construction based on distance.

 ③ Inventory the raw materials and calculate the daily material usage based on the actual measured area.

(4) Mechanical paving of surface layer

With thorough preparation, understand the weather trends for the day and in the near future, and determine that the ground moisture content is ≤10% before proceeding with the substrate paving process.

① Mixing and stirring the surface layer

a) The material mixing area should be covered with tape or plastic sheeting to avoid soiling the ground, damaging the construction quality, and affecting environmental cleanliness.

b) The capacity of the mixing tank should be 1.5 to 2 times the mixing volume. The mixing tank should be dry and clean before use.

c) When mixing materials, pour in the EPDM granules first, then pour in the pu binder.

d) The mixing time depends on the specific temperature and humidity. The basic mixing time is 3 to 5 minutes at 70% humidity and 25℃. At the same time, it is required that more than 99% of the granules are coated with adhesive before discharge. The well mixed material should be transported to the work area in a timely manner.

e) The total amount of materials required is determined based on the capacity of the mixer.

f) Prevent water from getting into the mixing container while stirring, because water reacts with and solidfys the pu binder.

g) Record the amount of material added and the mixing time each time in a timely manner, and summarize the results for each shift on the same day.

h) Steps: Feeding EPDM Granules→ Adding PU Binder → Mixing → Discharging.

② Mechanical paving of the surface layer

a) Before construction, ensure the ground is thoroughly cleaned and the moisture content is suitable for application before evenly applying the primer with a roller. Check and adjust the height of the paver.

b) Pour the well-mixed material into the feeding area of the paver;

c) When material leakage occurs on both sides of the effective width of the machine, manual replenishment should be carried out in time, and excess and spilled material should be cleaned up.

d) Use a trowel to scrape at small angles around the corners and drain holes, and add or remove material as needed to avoid depressions or bulges;

e) The bottom of the drain hole should be lined with fiberglass mesh to facilitate drainage;

f) Timely remove debris, insects, leaves, etc. In case they’re splashed onto the finished EPDM surface;

f) At the junction of the work areas of the two shifts, a trowel must be used to treat the joints to ensure that there is basically no height difference;

g) Determine the finishing position and apply the tape in advance;

h) The tape must be removed promptly after all material has been laid during the shift;

(5) Local trimming

1 Longitudinal and transverse construction joints and uneven areas need to be ground smooth with a surface grinder until there is basically no height difference;

2 Burrs and unremoved, solidified spilled material need to be smoothed with a grinder.

3 Excess material on both the inner and outer sides must be cleaned up promptly;

4 The outer corner angles should be consistent, controlled at around 45°, and the outer edge lines should be clearly defined.

(6) Marking the positioning lines

1 Draw lines

2 Lay out and mark the lines according to the  requirements and the standards.

3 After a second inspection confirms the accuracy of the markings, the lines will be marked with a width of 5 centimeters. The marking material used is polyurethane marking paint, which has the advantages of being wear-resistant, having strong adhesion, anti-yellowing, and being bright.

Important Notice:

1. The weight ratio of EPDM Granules and PU Binder is 5:1;

2. Mix the EPDM Granules and PU Binder thoroughly;

3. When paving the mixture of EPDM Granules and PU Binder, it must be compressed very tightly so that the finished surface is strong enough to bear the pressure.

4. The PU Binder can be too much viscous under low temperature, you may need electric thermal appliance to heat up the binder. When the binder is heat, the color turns into amber while the adhesion is not affected.

For More Details, Please Contact:

Simon Yin

WhatsApp: +86-13336122586

WeChat: +86-19032209551