How to Avoid Problems Such as Cracking and Unevenness of Epoxy Floors in Cleanrooms
2024.11.13
In the construction and maintenance of cleanrooms, the quality of epoxy floors is of crucial importance. Problems like cracking and unevenness of epoxy floors not only affect the aesthetics of the workshop but may also have a serious impact on the production environment and processes. Here are some key methods to avoid these issues.
I. Proper Treatment of the Base Course Is the Key Foundation
1. Inspection and Repair of the Ground Flatness
Before laying the epoxy floor, it is necessary to conduct a strict inspection of the flatness of the base course ground. Professional measuring tools such as levels and 2-meter straightedges should be used to check the height differences of the ground. For uneven areas, grinding, filling and other treatments should be carried out. If there are large pits on the base course ground, materials such as cement mortar can be used for repair to ensure that the flatness error of the base course is within the specified range. Generally, the flatness deviation within the range of a 2-meter straightedge should not exceed 2 - 3 millimeters.
2. Ensuring the Strength and Dryness of the Base Course
The base course ground should have sufficient strength to support the epoxy floor. If the strength of the base course is insufficient, it will be prone to cracking of the epoxy floor when subjected to pressure during subsequent use. For base courses with insufficient strength, such as loose concrete, reinforcement treatments can be carried out, for example, by using concrete strengthening agents. Meanwhile, the base course must be fully dried. A damp base course will affect the adhesion between the epoxy floor and the base course, resulting in hollowing and cracking of the floor. Generally, the moisture content of the base course should not be higher than 6% - 8%, which can be detected by a humidity tester.
II. Selection and Quality Control of Epoxy Floor Materials
1. Selection of High-Quality Materials
Selecting appropriate epoxy floor materials is an important part of avoiding problems. According to the specific usage requirements of the cleanroom, such as whether there is chemical corrosion and the magnitude of the load-bearing weight, corresponding epoxy materials should be selected. For example, for workshops in contact with acid-base and other chemical substances, epoxy materials with good chemical corrosion resistance should be selected; for workshops bearing heavy equipment or with frequent vehicle traffic, high-strength and high-toughness epoxy floor paints should be chosen. Meanwhile, attention should be paid to the brand of materials and quality certifications, and products with a good reputation and quality assurance should be given priority.
2. Accuracy of Material Proportioning and Mixing
The proportioning and mixing of epoxy floor materials have a great impact on the quality of the floor. Operate strictly in accordance with the proportioning provided by the material supplier, and use precise measuring tools such as electronic scales. During the mixing process, ensure that the mixing is even so that components such as curing agents and resins are fully mixed. Uneven mixing may lead to incomplete local curing of the floor, resulting in problems such as inconsistent hardness and cracking. The mixing time and speed should be controlled according to the material instructions. Generally, the mixing time should not be less than the specified duration to ensure the stable performance of the materials.
III. Standard Execution of the Construction Process
1. Control of the Painting Thickness
The painting thickness of the epoxy floor should be moderate. If the painting is too thick, during the drying process, due to the inconsistent drying speed inside and outside, shrinkage stress will be easily generated, leading to cracking of the floor. Generally speaking, the painting thickness of each layer of epoxy floor paint should not exceed the specified value. For example, the thickness of the primer is usually 0.1 - 0.2 millimeters, the thickness of the intermediate coat paint is 0.3 - 0.5 millimeters, and the thickness of the topcoat paint is 0.2 - 0.3 millimeters. During the construction process, tools such as wet film thickness gauges can be used for real-time monitoring and adjustment.
2. Suitability of the Construction Environment
The construction environment has a key impact on the quality of the epoxy floor. Temperature and humidity are two important factors. The ideal temperature for the construction of the epoxy floor is generally between 15 - 25 °C, and the humidity is below 75%. A too low temperature will cause the floor paint to dry slowly and affect the curing effect; a too high temperature may cause the floor paint to dry too quickly and result in surface cracks. Excessive humidity is prone to causing phenomena such as whitening and blistering of the floor. Meanwhile, keep the environment clean during the construction process to avoid impurities such as dust from being mixed into the floor paint and affecting the flatness and smoothness of the floor.
3. Professional Quality of Construction Workers
The skill level and experience of construction workers directly determine the construction quality of the epoxy floor. Professional construction workers are familiar with the construction process and process requirements of the epoxy floor and can correctly operate construction equipment such as spray guns and scrapers. During the brushing, rolling or scraping process, they can ensure the uniformity and continuity of the coating and avoid problems such as missed coating and uneven thickness. Therefore, an experienced and professionally trained construction team should be selected for the construction of the epoxy floor.
IV. Maintenance and Care during the Use Process
1. Avoiding Overload
During the use of the cleanroom, strictly control the load borne by the floor. Avoid heavy equipment, vehicles, etc. from staying on the floor for a long time or traveling frequently. For areas with heavy equipment, measures to distribute the weight can be taken, such as using load-bearing pallets, to prevent the floor from cracking due to excessive pressure.
2. Regular Cleaning and Inspection
Establish a regular cleaning system, use appropriate cleaning tools and cleaners to keep the surface of the epoxy floor clean. Meanwhile, conduct regular inspections of the floor to check for early signs of problems such as cracks, wear and bulging. Once problems are found, take timely repair measures to prevent them from worsening. For small cracks, epoxy repair agents can be used for filling; for large areas of damage, the floor should be re-laid or repaired according to the actual situation.
Through the above measures in aspects such as base course treatment, material selection, construction process and use and maintenance, problems such as cracking and unevenness of epoxy floors in cleanrooms can be effectively avoided, ensuring that the epoxy floors can stably serve the production environment of cleanrooms for a long time.
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