Morricite Installation Guidelines - Master Terrazzo · 2019. 12. 25. · Thin-Set Epoxy Terrazzo...

Thin-Set Epoxy Terrazzo Flooring SystemIntroductionMorricite epoxy terrazzo is a poured-in-place nominal 3/8” or 1/4” lightweight decorative flooring. It consists of thermosetting epoxy resins and selected aggregates (marble, granite or glass) that are troweled in place, then ground and polished. With the exception of the finish sealer, the entire resin system is composed of 100% solids low odor epoxy resins and hardeners.

System Components• Morricite Primer• Morricite Thin-Set Epoxy• Morricite Grout Hardener• ColorFlex Flexible Epoxy• SealOn Clear Acrylic Sealer / Finish• MasterFlex Membrane (Optional)• MasterFlex Membrane Fabric (Optional)• MVP 300 Moisture Barrier

Thickness• Nominal 3/8” (9.5mm)• Nominal 1/4” (6.3mm)

Equipment ListSafety Equipment

• Commercial exhaust fans or air movers• Industrial rubber gloves and/or disposable work gloves, wipe rags• Dust masks• Protective hand cream, soap and water• Respirators with organic vapor cartridges and dust masks.• Shotblasting, concrete grinding or other equipment for mechanically abrading surface. Industrial vacuum, if prepping with grinders or scarifiers• Regular and stiff-bristled brooms, wheelbarrows, shovels, etc.• Masking tape, paper and/or polyethylene for protection of adjacent areasMixing & Installation Equipment

• High intensity, temporary lighting and extension cords• Plaster or mortar type mixer• Slow speed drill mixer with Jiffy type blade or bucket mixer like Kol’s Mixal

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• Wheelbarrow• Gauged rake or trowels for spreading mortar evenly• Narrow trowels, magnesium floats, spring steel trowels, long handled paint rollers• Power trowel

Project PreparationGeneral Concrete Slab Requirements

• Substrates in contact with ground should have a non-capillary layer of coarse granular fill and an effective vapor barrier to break capillary contact with the soil and help prevent potential problems from moisture migration. The vapor barrier must be in intimate contact with the underside of the slab. Vapor barrier should also have taped seams, be properly terminated at all slab edges, and be properly detailed at all penetrations through the slab.

• Concrete should be structurally sound and suitable for placement of a high performance, bonded finish. Typically, a minimum 3,000 psi (20.69 MPa) compressive strength and a maximum water/cement ratio of 0.45 are required. All Type 1 Portland Cement Concrete needs to cure for a minimum of 28 days to allow adequate hydration, strength development and escape of moisture.

• The fully cured concrete slab should show a moisture vapor emission rate of 3 lb. per 1,000 sf per 24 hours or less as measured by the calcium chloride test (ASTM F1869-98). The test site should be at the same temperature and humidity expected during normal use. If this is not possible, then the test conditions should be 75 ± 10°F (23.9 ± 5.5°C) and 50 ± 10 % relative humidity. Maintain these conditions 48 hours prior to, and during testing. If the MVE exceeds 3 lbs., contact MTT for further evaluation and recommendations.

• Terrazzo should not be placed when the surface temperature of the slab is within 5°F of the ambient dew point.

Concrete Substrate Preparation

• Surface preparation for all concrete slabs should meet four basic criteria beforeinstallation of Morricite Epoxy Terrazzo:

• Removal of Bond Inhibiting Contaminants shall include, but not be limited to, removalof oils, grease, wax, sealers, curing compounds and other hydrocarbon based materials.

• Creation of Concrete Profile to enhance the mechanical bond of the new terrazzo. Theideal profile should be 5 to 10 mils (0.13 to 0.25 mm) as defined by measuring theaverage distance from the peaks to the valleys in a cross section view of the concrete.

• Repair of Surface Irregularities including but not limited to bugholes, cracks, scaling,spalls, fins and honeycombs is required to provide a consistent, uniform finish in theMorricite installation. Extensive scaling and surface deterioration may require grinding orleveling the entire area with a coat of epoxy prior to the floor installation.

• Replacement of Structurally Deteriorated Concrete. All repairs shall be done inaccordance with The International Concrete Repair Institute (ICRI) Bulletin “Surface


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Preparation for the Repair of Deteriorated Concrete.” Morricite will not perform properly when applied over weak, deteriorated, punky concrete. Flash patch, gypsum based patching cements, or high density cement self-leveling underlayments are not acceptable. Patching material shall be MorriFill™ Epoxy Fill, MonoFill™ Polyacrylate Fill Mortar, or a quality, polymer modified cement repair mortar engineered for the type of concrete deficiency being repaired.

• Vacuum-Grit Blasting or Shotblasting is the preferred method of surface preparation for most installations. Shotblasters remove surface contamination, profile, and vacuum clean the concrete in one process. The size of shot and speed of the machine can be adjusted. Shotblasting is a dry preparation process allowing for the floor installation to begin immediately after completion of prep work. The mechanical blasting also helps identify weak areas in the surface of the concrete (i.e. concrete pours that were rained on, or poorly finished concrete). Shotblasting also removes most curing compounds.

• Terrazzo Grinding with coarse or diamond stones may also be used for preparation, taking care to open surface pores. Care should also be taken to allow surface to thoroughly dry after any wet grinding.

• The surfaces should be thoroughly vacuumed to remove surface dirt and dust following any type of mechanical preparation.

Environmental Requirements

• Surface and air temperatures must be a minimum of 55°F (12°C) during the entire installation and curing process. Morricite becomes harder to pull and close at colder slab and air temperatures. The curing process also lengthens.

• Provide sufficient air movement to prevent condensation on surface during installation. The HVAC should be turned on. The surface temperature of the slab must be at least 5°F greater than the ambient dew point.

Planning Installation• Insure that all materials and equipment are on location to match approved samples

including:• MasterFlex Membrane if specified• Resin and hardener for primer, matrix, and membrane, if required• ColorFlex Joint Filler for terrazzo control joints• Aggregates (i.e., marble, granite, glass, etc.)• SealOn terrazzo sealer• Solvents for cleaning• Stop strips and divider strips• Maintain liquid materials and aggregates at proper temperatures in cold and hot weather • Carefully measure liquid and components accurately to maintain correct mixing ratioStrips

• Consult National Terrazzo & Mosaic Association Information Guide or strip manufacturer


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• Bond strip to substrate with complete ribbon of epoxy or contact cement. Hot glue may be used for temporary bonding.

Aggregates

• Typically a blend of marble, granite, synthetic, mother of pearl, or glass chips• Maximum chip size for 3/8” thickness is #2, 1/4” thickness is #1• The use of marble dust as a filler will slightly change the color of the resin matrixMembrane (Optional)

• Use MasterFlex Membrane at thickness specified in MTT Concrete Substrate Crack Detailing Guidelines

Application ProceduresMasking

After suitable preparation has been completed, mask all surfaces that require protection. If base is required, mask appropriately to protect.

Cove Base (Optional)

• A suitable cap strip is recommended• Install strip or temporary screed at the top of the cove• Use brush or roller to apply blended epoxy primer.• Mixing and installation procedures are the same as floor grade, however the field addition

of small amounts of fumed silica such as Cab-O-Sil® or Aerosil® to create a gel will aid in placement of the resin.

• Thoroughly mix resin and hardener with a mechanical mixer at the correct mixing ration. Slowly add the fumed silica until the desired gel consistency is achieved.

• Add 1/3 volume of blended aggregate to resin/hardener mix. Mix for 30-45 seconds, then add filler. Allow to mix for 30-45 seconds and add remaining 2/3 of blended aggregate. Mix until thoroughly blended.

• Transport to work area in wheelbarrows or appropriately sized containers• Trowel from floor up, with straight edge trowel• Trowel out on floor about 4” (10.2 cm) to temporary screed or stop strip• Place extra epoxy mix in radius and smooth with small radius coving trowel approximately

3/4” (19.1 mm) to 1” (25.4 mm)• Lubricate trowel sparingly with Odorless Mineral Spirits, Aromatics 100, or Solvesso. • Application of floor can be blended in with coving material while it is still soft, if strips are

not used.• After resin hardens, grind base with appropriate coarse and intermediate stones with base

grinding equipment, taking care not to cut into base at an angle.• Mix Morricite Epoxy Resin and Grout Hardener at 4:1 ratio and brush apply into base

twice (brush apply second coat after first coat has set for 15 to 30 minutes).• Strike off excess with spring steel trowel to prevent runs.


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Cracks and Non-Moving Joints

• Hairline cracks shall receive a detail coat of epoxy primer with 3" fiberglass tape embedded in the primer.

• Fill cracks greater than hairline but less than 1/16" wide after surface preparation with MasterFlex Membrane. Place a 25-30 mil detail coat (50-65 sq. ft. per mixed gallon) of Membrane over crack and embed 6” MasterFlex Membrane Fabric into the MasterFlex epoxy membrane. If membrane cannot be coated within 24 hours, sand treated cracks prior to applying primer.

• Fill cracks greater than 1/16" with MasterFlex Membrane. Place 30 mil detail coat so that MasterFlex Membrane extends at least 9” to 12” on each side of crack or joint. After the MasterFlex Membrane has leveled, install a piece of precut MasterFlex Membrane Fabric into wet MasterFlex Membrane. Smooth the cloth with a flat steel trowel, allowing cloth to remain exposed on the surface of the MasterFlex Membrane. Be sure that edges of the MasterFlex Membrane fabric are encapsulated and are not loose. If air pockets exist, cut with the edge of the steel trowel and work into wet Membrane.

Full Membrane System (Optional)

In some cases, it may be desirable to utilize full coverage of MasterFlex Membrane under all or part of the Morricite terrazzo floor. Please consult MTT about specific detailing at terminations, building columns and base conditions. As a general rule, it is recommended that the MasterFlex Membrane should extend to the edges of all wall details. The Morricite terrazzo system is poured to just short of the edge of the membrane. Utilize a termination strip at these edge details and fill with ColorFlex at edges. Depending on ambient temperature conditions during installation, subsequent construction, and final use conditions, additional movement joints may be required in the Morricite terrazzo topping. Consult MTT for specific job conditions. THE USE OF MASTERFLEX MEMBRANE WILL NOT ALLEVIATE THE POTENTIAL FOR CRACKING FROM VERTICAL MOVEMENT. AT ANY LOCATION WHERE VERTICAL MOVEMENT IS ANTICIPATED, THE SPECIFIER MUST DETAIL A MOVEMENT JOINT ALL THE WAY THROUGH THE TERRAZZO SYSTEM TO MATCH THE JOINT IN THE SUBSTRATE.

• MasterFlex Membrane is typically self-priming in cases of well-prepared, dense concrete substrates. However, over porous concrete or wood substrates, Morricite primer must be used prior to installing the MasterFlex membrane. To avoid working in tacky or uncured primer, prime the day before and lightly seed primer with 50 mesh sand to enhance the mechanical bond of membrane.

• Where reinforcing has been specified, precut MasterFlex Membrane Fabric to fit the area to be covered with MasterFlex Membrane. Lay cloth on floor with the side that was inside the roll facing down. Edges of cloth will be overlapped. Periodically place weight on cloth to help prevent rollup at edges. Whenever possible, perform this step the day before installing the MasterFlex membrane. This will help to achieve maximum flatness of cloth before membrane installation.

• Snap chalk lines on the floor to the width of each piece of cloth to be placed in the MasterFlex membrane.


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• Thoroughly mix MasterFlex Membrane resin with hardener at a 2:1 ratio with a drill and paddle mixer. A clean five gallon bucket works well for this application.

• Apply Membrane between first set of chalk lines to fit the size of precut fabric with a 1/4” V notched trowel or 3/16” V notched squeegee at a rate of 50-55 sq. ft. per gallon, to achieve 30 mils thickness. Allow membrane to level until no ridges are showing.

• Lay precut fabric into MasterFlex membrane. Start at one edge and with a flat steel trowel, work the cloth into membrane until the membrane begins to come through cloth, but leave the pattern of the cloth exposed. If an air bubble exists under the cloth, cut the cloth with the edge of the trowel and lay fabric back into membrane.

• Divider strips should be installed the next day on the top of membrane utilizing Morricite Primer to bond strips to the membrane.

• If the MasterFlex Membrane will not be covered within 72 hours of installation, it must be wiped with a solvent of odorless mineral spirits (OMS) completely prior to installing primer and terrazzo. In humid or cooler temperature environments a blush or haze may appear on the surface. This can also be removed by solvent wiping.

Priming the Floor

• Thoroughly mix Morricite Primer resin with hardener at a 2:1 ratio and apply by roller, trowel, or squeegee at a rate of 175-250 sq. ft. per gallon, depending on substrate porosity.

• Prime only amount that can be covered within a 3-4 hour time period.• If primer must sit longer than 3-4 hours, lightly seed with 30 mesh sand to enhance

mechanical bond of the Morricite resin.Epoxy Matrix Application

• Proper level of floor is HIGHLY important.• BEFORE EVERY MIX, STIR RESIN PART A TO DISPERSE ANY PIGMENT THAT MAY

HAVE SETTLED. If material is in drums, roll drums or use bung mixer. Material may have developed “false gel” if shipped during colder temperatures. Proper mixing will restore normal viscosity prior to the addition of the hardener.

• Combine Morricite resin and hardener at 5:1 ratio (for standard cure system) and mechanically mix for 2 minutes.

• Add 1/3 volume of blended aggregate to Morricite resin/hardener mix. Mix for 30-45 seconds, then add filler. Allow to mix for 30-45 seconds and then add remaining 2/3 of blended aggregate less any aggregate held back for surface seeding.

• Transport to work area in wheelbarrows or appropriate containers• Trowel apply evenly over floor. If seeding surface with additional chips, broadcast floor

evenly and trowel again to embed seeded chips.• Close or finish the surface of the Morricite with power trowel whenever possible to provide

maximum density• The amount of filler used can be varied to achieve good workability of the mix.• The first mix normally will be dry. Hold back a small amount of chips and filler in the initial

batch or until mixing equipment is thoroughly wetted out.


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Finishing

• Grind Morricite after minimum overnight cure. If slab or air temperatures are below 65°F (18°C), system may require additional cure time before grinding.

• Rough grind with 24 grit Carborundum stone or with compatible diamond plate.• Follow initial grind with 80 or finer grit stone.• Before grouting, the floor should be thoroughly cleaned, rinsed, vacuumed and allowed to

dry.• To grout, thoroughly mix Morricite Resin with Morricite Grout Hardener at a 4:1 ratio. • Spread Morricite Grout with a spring steel trowel or non-marking squeegee. After grout

has leveled, surface may be lightly dusted with marble dust. On black and other deep colors, eliminate marble dust and substitute black beauty powder, or completely eliminate filler.

• Polish with 80 grit or finer grit stone as suitable for project conditions until all grout is removed from the surface.

• After polishing, the terrazzo surface should show a minimum of 70% chips per NTMA standards.

Sealing the Floor

• A penetrating sealer such as SealOn (solvent based) is best used to highlight the chips and help prevent subsequent staining.

• Surface preparation is very important before applying sealer – make sure that terrazzo is dry and free of dust. Sealer will be applied in 2or 3 coats. Thinner, uniform coats are always better than thick coats.

• Utilize 24 oz. Rayon mop head with clean bucket and ringer. Pour SealOn or AquaSeal over mop head. Tamp out mop in wringer until uniform – not too wet or too dry.

• Start by cutting in edges against wall or baseboard first. When one side of mop begins to dry, roll to other side without removing mop from the floor. When mop is dry, apply more sealer and tamp in wringer as before.

• Apply sealer in main area by walking backwards while making tight figure eights, 4’-6’ wide with short, overlapping strokes. After first coat dries, apply second coat making figure eights at a 90° angle to first coat.

• If desired, sealer may be buffed with a white pad after 24 hours to further harden surface.

CleaningClean all equipment and tools before epoxy starts to cure, with appropriate solvent such as Xylene. Maintain safety recommendations when using solvents. Once the floor has been sealed, utilize a neutral pH cleaner. Consult MTT for stripping and resealing.

Maintenance and Temporary Protection• Do not allow the installation of temporary protection while the floor may be wet.

Entrapped moisture may oxidize strips and create stains in terrazzo.• Consult the NTMA Information Guide for the care of terrazzo


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Precautions• DO NOT alter the recommended mixing ratios of fluids. Changing resin-hardener ratios

will drastically alter physical properties.• DO NOT allow traffic on the floor for a minimum of 15 hours after completion of troweling

operation.• DO NOT cover the floor with plastic or other protection course if the floor is wet from

grinding operation.• When using brass strips, remove slurry and moisture frequently during grinding operation.

At completion of the grinding, remove moisture along the strips. • DO NOT install under steam kettles, ovens, ranges, or when constant or regular thermal

shock exposure to 150°F (65°C) or higher water or other liquids. (Consult MTT)• DO NOT start any job unless the conditions are acceptable including: temperature,

humidity, dew point, ventilation, condition of substrate, thorough moisture check, preparation, access to work area, lighting, cooperation of other trades, etc.

• DO NOT bond the edges of Morricite terrazzo to the concrete when installed over full coverage MasterFlex Membrane applications.

• DO NOT allow construction traffic on the floor between the installation of MasterFlex Membrane and the Morricite terrazzo installation.

Notes Regarding MaterialsAll quantities are approximate and will be affected by job conditions and workmanship. MTT cannot be responsible for actual coverages.

Safety• Provide adequate ventilation.• Wear protective clothing, avoid skin contact.• Use protective hand cream and wash frequently with warm soapy water.• Use a respirator with organic vapor cartridge filters in poorly ventilated areas.• These materials should be used only by qualified terrazzo installers. Carefully review

sections on subfloor preparation and safety, and be sure to read container labels.• THOROUGHLY REVIEW MATERIAL SAFETY DATA SHEETS (MSDS) PRIOR TO

INSTALLATION.


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Warranty InformationValues stated herein are typical values based on periodic testing and product experience. MTT DISCLAIMS ALL OTHER EXPRESS OR IMPLIED WARRANTIES, INCLUDING WITHOUT LIMITATION THOSE OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Where customer demonstrates non-conformance of product to typical values stated herein, MTT will supply replacement product or, at its option, credit Customer’s account for the purchase price of non-conforming product. Recommendations herein as to the surface preparation, application, maintenance, and other matters involved in storage, handling, or use of product are based on best information reasonably available to MTT. Because MTT has no control over such matters, or over substrate or other conditions that may affect ultimate performance, Customer has the obligation to determine suitability of product for the intended purpose, and MTT SHALL HAVE NO RESPONSIBILITY FOR ANY CONSEQUENTIAL, INCIDENTAL, SPECIAL, EXEMPLARY OR PUNITIVE DAMAGES BUT ONLY FOR THE REPLACEMENT OR CREDITING REMEDY ABOVE. All claims for replacement or crediting must be made within one year from date of shipment. The sale and purchase of product from MTT are subject in each case to MTT’s Terms and Conditions of Purchase.

Date Revised: 8/2012

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Morricite Installation Guidelines - Master Terrazzo · 2019. 12. 25. · Thin-Set Epoxy Terrazzo...

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