Category: Application Tips
Home / Application Tips /

Choosing the Right Floor Coating for Forklift Battery Charging Areas

One area that consistently demands attention is the forklift battery charging station. These zones take a beating from acid spills, heavy traffic, and general industrial wear and tear. Concrete damage here isn’t just an aesthetic issue; it’s a safety and cost concern.

Standard floor paint in these zones is often only a short-term fix. The unique stresses – corrosive acid, heavy point loads, constant abrasion – mean it breaks down quickly, leading to ongoing repairs and safety concerns. Our high-performance coatings, chemical resistant coatings can withstand the abuse.

Why Ordinary Floor Coatings Don’t Cut It

Battery charging areas are particularly hard on concrete floors:

Acid Attack: Battery acid doesn’t just sit on the surface; it actively degrades concrete. This weakens the structure over time, leading to cracks, dusting, and an uneven surface.

Heavy Loads and Abuse: Forklifts are heavy, and their constant movement abrades the surface. Coatings need to withstand this constant stress without delaminating or wearing away prematurely.

Safety and Maintenance: Damaged floors are trip hazards. A smooth, non-porous coated floor is easier to keep clean, minimizing slip hazards. This is a big win for safety compliance.

Thermal-Chem’s Battery Charging Area Floor Coating System: 755 NovoClad

Our 755 NovoClad novolac type epoxy coating is designed for the challenges of battery charging areas:

Superior Chemical Resistance: 755 NovoClad creates an impermeable barrier that stands up to battery acids and other industrial chemicals, protecting the concrete substrate.

Exceptional Durability and Abrasion Resistance: Our battery charging systems are built to handle heavy industrial traffic, resisting wear and tear far longer than standard paints. This translates directly to less downtime.

Enhanced Safety and Cleanliness: A seamless, non-porous coated floor is significantly easier to clean, preventing the accumulation of contaminants and reducing slip risks.

Epoxy Safety Striping

Thermal-Chem also manufactures epoxy safety striping to clearly mark walkways, charging zones, and safety perimeters. It improves visibility, helps keep traffic organized, and reinforces safety protocols. Integrating this with a full floor coating system just makes sense for a comprehensive solution.

 

Thermal-Chem Times #4 – All About Top Coats!

Featured Product

Topcoats

Here’s a tip… quality topcoats are a part of your brand image.  If your topcoat doesn’t perform, your customer is probably blaming you. Avoid these problems with Thermal-Chems’ time-tested portfolio of topcoat products.

tc2
tc1

Your resinous flooring solutions start with a reliable coatings manufacturer. Thermal-Chem provides just that!  Quality products backed by industry leading customer service and competitive pricing. Learn more about ThermalChem Top Coats

AROUND THERMALCHEM

Josh Cotto

Here we grow again!

We are pleased to welcome Josh to Thermal-Chem.  Josh’s experience will be a great fit in his new position as Plant Manager.

With 15 years of experience in project management and logistics, Josh will play an integral role in maintaining Thermal-Chem’s top-class service.

PRO TIPS

Avoiding Epoxy Sensitization

skin problems

Our industry has experienced many changes in the last few years.  One trend we see is the number of contractors that are being affected by rashes, difficulty breathing, irritated eyes and other health problems.

Epoxy was invented in 1930’s. Have there been problems like this before?  Yes, but not to the magnitude we see today.  Raw materials pricing, formulation changes, and poor general housekeeping are likely are the culprits.  

Here are some tips to avoid epoxy sensitization:

  1. Wash your hands as much as possible with warm water and soap.
  2. Wear long sleeves and protective gloves when mixing or applying products.
  3. DO NOT clean your skin with any type of solvent.
  4. If you think you have had this reaction, hydrocortisone cream is applied generously and often to the affected areas, and avoid exposure for 2-4 weeks.
  5. Train ALL new employees on the proper methods and products used for PPE.
  6. Hold tool-box safety meetings and put this on your agenda at least twice annually.

Knowing the components in the products you are installing is important to monitor.  Become familiar with SDS for the products your crews use.  This is a medical condition that could possibly lead to these factors and could cost you good quality crew members.

Thermal-Chem Times #3 – AmorGel #729, Cold Weather Tips and Buy 3 get one Free!

Featured Product

#729 ArmorGel – 100% solids polymer gel for pre-filling concrete surface defects such as pitting or cracks

cracks

ArmorGel is an ultra-high viscosity, two-component, 100% solids polymer gel for pre-filling concrete surface defects such as pitting or cracks.  This ultra-high build product is extremely durable and easy to use.

#729 ArmorGel offers the following advantages:

  • Easy 2-1 mix ratio
  • 100% solids, no offensive odors, VOC compliant
  • Superior adhesion to various substrates
  • Available in both regular and fast cure options
  • Can be used for both cant cove and block filler for CMU

Make your project patching go quickly and increase your bottom line by using this as your go-to patch materials. (See below for a valuable offer on purchasing #729 ArmorGel).

AROUND THERMALCHEM

holiday

We will be closed on 12/26/2022 and 12/30/22 for the Holidays.  We wish you and yours a Happy and Safe Holiday Season.

Please note: while we may be open many carriers are on limited Holiday schedules.  If a carrier will not be timely in their pick-up of orders, we will let you know.

wocWORLD OF CONCRETE

Please let us know if you will be attending the World of Concrete in Las Vegas 1/16/23-1/20/23.

PRO TIPS

blistersFLOORING CONTRACTOR: COLD WEATHER INSTALLATION TIPS:

As the weather continues to drop to winter temperatures, we highly recommend NOT using a kerosene or propane heater to warm up your project space.  The forms of heat can leave emissions which will fall to the floor and create both fisheyes (separation blisters), and micro bubbles in your coating.  Additionally, be aware that storing and transporting polymer materials will increase the viscosity of the product.  Please try and allow your materials to stay above 50 degrees F and bring them to the jobsite to allow them to acclimatize. (Hint-Use a thermometer to check both your substrate and product temperatures.

INFLATION BUSTER!

armor gelBuy 3 kits of #729ArmorGel and receive a 4th kit at NO CHARGE (excluding freight).

CONTACT: sales@thermalchem.com to place your order!

Thermal-Chem Times #2 – Newsletter

Featured Product

Thermal-Chem’s #726 Cove Base Kit
Installing Cove Base Has Never Been Easier

cove 1

Our #726-CV epoxy base cove system is ideal for use in areas that require a seamless transition from floor to wall. This integral monolithic system is ideal in areas that require clean and hygienic environments such as commercial kitchens or medical facilities. This trowelable kit comes with everything needed for ease of use.

#726-CV takes the guesswork out of mixing the correct ratios of epoxy, sand and thickening agents to try and create epoxy coving material at the job site. Each kit contains everything you need to mix the perfect consistency epoxy cove material every time.  It contains 72 ounces of thickened up Part A and B, with a bag of premeasured sand that will cover 23 lineal feet of 4″ high cove base.

AROUND THERMALCHEM

tcu 1Thermal-Chem University Graduates 1st Class

Thermal-Chem is proud to announce that our contractor training has begun. This past month we had a dozen contractors from various parts of the Midwest attend Thermal-Chem University. This one-day training program combined classroom and hands-on opportunities to try various Thermal-Chem products and systems. From setting up a proper mix station, understanding proper surface prep, how to install our metallic system, DECOESSENCE, and how to write effective proposals were just a few of the topics covered.

Our next class will be November 9, 2022, at our facility in Broadview, IL.

Contact Michele at Thermal-Chem to put your name on the list for the next class. Classes are limited to 10 attendees.

PRO TIPS

Screen Shot 2022 10 02 at 3.56.39 PMHOW TO AVIOD THE “RING OF DOOM”

Several times a year we get a call from an upset contractor that on their last project the epoxy had some “sticky” spots throughout it. This is likely a result of flipping mixing buckets over and trying to use every drop.

Sometimes it is nearly impossible to get every part of resin to mix with every part of hardener. When you flip over the mix bucket, you are putting unmixed product on the floor, thus leaving the soft spot. This is also referred to the “ring of doom” by some contractors.

Thermal-Chem Times #1 – Newsletter

Featured Product

#211 VaporGard

211 VaporGard
Moisture-related problems continue to plague the entire flooring industry with estimates that failures cost approximately 1 billion dollars per year. As a contractor, testing for any moisture is a must! According to an industry survey, somewhere between 80%-90% of all flooring contractors do not own or properly use moisture testing equipment. Construction, especially residential, is on a super-fast track with the housing boom. Resinous flooring contractors are being asked to install a flake garage floor in 2-3 days. Thermal-Chem’s #211 VaporGard is a great, inexpensive solution for slabs that have moisture. Our product has been recently tested by an independent leading moisture testing lab. The results showed when applied at 16 mils, our product will reduce moisture vapor transmission by over 80%! This lab also did 3 sets of pull-off tests, and each tested over 500 psi, where the concrete failed. Some additional features:

  • 100% solids epoxy formulation
  • Extremely easy to apply
  • Extremely low viscosity to allow for deep penetration (see pull-off test results)
  • VOC Compliant with ALL U.S. regulations
  • Can be applied to a diamond ground substrate as long as a CSP 3 is achieved.
  • A very competitive price point

THE BEST INSURANCE A CONTRACTOR CAN BUY!

AROUND THERMALCHEM

 

A WARM WELCOME TO EILEEN.

eilienAfter more than 25 years in the Industrial Flooring industry, Eileen joins Thermal-Chem as our Key Account Manager. With long-term relationships with contractors across the country, Eileen understands the needs of our customers and the importance of getting the right materials for each project, delivered on time.

Eileen’s previous experience has focused on Customer Service/Inside Sales, Contractor Training and Accounting. At Thermal-Chem, she will also be involved in logistics to reduce transit times and freight costs for our customers.

 

PRO TIPS

INSTALLERS: MANAGE JOB TEMPERATURE DURING INSTALLATION!

02 covered windowAs the entire world is experiencing intense heat, here is a small trick that may help eliminate some outgassing bubbles on your residential projects.

Cover all the windows with black plastic sheeting or even use black trash bags. When the project is complete, remove the trash bag(s) and use them for project debris.

Resinous products like epoxies and polyurea cause heat during their curing process. The extra heat from windows can cause tiny bubbles or crater blisters.

How Does pH Affect Polymer Coatings Ability to Adhere?

Thermal-Chem believes that when applying our products, you should have as much information as possible about the concrete you are about to coat. 

Let’s talk about pH and how easy it is to test, and the failures that can occur on a slab of concrete that is not within the normal standards.

pH (power of hydrogen) is a scale that is used to measure how basic or acidic a water-based solution is.  This scale ranges from 0-14.  If a solution has a pH less than 7, it is considered acidic.  If a solution has a pH greater than 7, it is considered basic or alkaline.  A pH level of 7 is considered neutral.  For example, water has a pH of 7.

The ideal pH level of a concrete substrate, whether too high or too low, will affect the overall adhesion or bond strength.  The ideal pH value for applying polymer systems such as those manufactured by Thermal-Chem is 7, although 6.5-8 is acceptable.  See the scale above.

Testing a concrete substrate is quite easy.  You will need a bottle of water (tap water may alter the results), and a litmus pH strip.

  1. Clean the concrete to be free of dirt, dust, or anything preventing the substrate from being porous.
  2. Pour a puddle of water 1”-2”, and allow to stand for at least one minute.
  3. Place the pH strip into the water and remove immediately.
  4. Compare the color of the pH strip with the above color chart to determine the pH.

Dealing with abnormal readings.  Fresh concrete will typically test between 10-12, so make sure you are not dealing with a new piece of concrete.  Additionally, if you have already prepared your concrete either by diamond grinding or shot-blasting this, will also cause high readings. If either of these are not factors to consider, remediating concrete to a neutral reading is not difficult.  Usually, a neutralizing detergent applied to the concrete and then rinsed will bring down elevated readings.  Highly acidic surfaces can be neutralized by using a diluted solution of caustic soda or baking soda.  Let this sit on the concrete for 10-15 minutes then rinse at least twice.

Don’t let a project fail because of a lack of performing a 10-minute test.  Be a true professional and know your project. Contact Thermal-Chem for more information about our products and to help make your next concrete flooring project a success.

How to prevent concrete coating failure due to moisture

The largest financial problem in the resinous coatings industry is failure due to moisture.  Some estimate this problem to cost over 1 billion dollars per year in the United States.  This article will hopefully shed some light on not only the problems but how to correctly test a concrete slab for moisture.

Let’s start by looking at ways flooring can be exposed to moisture in the concrete.

  1. Water of Convenience:  Simply stated this is the water used by the concrete company to keep the concrete “wet” enough to be able to properly place it.  The typical cement to water ratio should be .45-.50, However, today we are seeing these ratios climb to give the concrete crew more time to “work” with the concrete.  This water typically hydrates the curing process and then excess water evaporates.
  2. Improperly Installed Vapor Barrier:  This is material placed before the concrete is poured with the design to block or slow down moisture from the ground finding its way into the slab.  There are design standards for this, with the main goal being to reduce the permeance of water into the concrete.
  3. Inadequate Water Drainage:  Water from rain or snow melt that doesn’t properly drain away from the building.
  4. Concrete Being Exposed to Rain/Snow:  If the building and concrete are exposed to these weather elements before it becomes enclosed, it will add unexpected water to the concrete.

As a contractor, testing for moisture in concrete is a must.  Yet it is estimated that 90% of all flooring contractors do not possess the proper testing equipment, and those who do own the equipment do not follow ASTM guidelines.  The largest ASTM guideline not being accounted for is NOT TESTING A CONCRETE SLAB THAT HAS HAD AT LEAST 48 HOURS TO ACCLIMATE TO IT’S SERVICE TEMPERATURE.  Improper testing leads to misinformation which leads to bad decisions which leads to flooring failures.

In today’s construction environment everything is about time and money.  Building owners are anxious for their building to be ready to occupy, and the general contractor makes sure that happens.  This “fast-track” method typically does not account for the 72 hours to allow a proper moisture test to be completed.  If the testing is completed and shows high moisture content, there are another few days to properly install a topical moisture mitigation product, such as Thermal-Chem’s #211 VaporGard.

Two tests that provide false negative or false positive tests are the Plastic Sheet Method and the use of a moisture meter with pins that are pushed into the concrete.  If you are going to rely on these tests, it is recommended that you exclude any future problems as a result of moisture damage in the Terms and Conditions of your proposal.

The two tests that are typically accepted by ASTM and architects are the F-1869 Calcium Chloride Test and ASTM F2170 In-situ Relative Humidity.  The calcium chloride test presents its results in lbs. per 1000 square feet, the relative humidity results are given in the percentage of moisture in the concrete.

Our #211 VaporGard has been independently tested lab in 2022, and the 4 samples effectively reduced moisture vapor transmission by 80%.  Thermal-Chem is committed to helping you complete your projects from the beginning through the useful life of the products you have installed.  If you have any questions, please call us at 1-800-635-3773.

How to Prep Concrete Surfaces for Epoxy Coatings

Several years ago, the International Concrete Repair Institute (I.C.R.I.) released Technical Guideline No. 310.2R-2013 “Selecting and Specifying Concrete Surface Preparation for Sealers, Coatings, Polymer Overlays, and Concrete Repair”.  This guideline provided ten surface profiles that were considered to be acceptable for various types of systems to be applied to the concrete.  The purpose of this guideline was to provide an industry standard to reduce the large number of coating failures due to insufficient concrete profiles. Surface Prep Profiles as Defined by ICRI No 310.2R-2013 Surface Prep Profiles as Defined by ICRI No 310.2R-2013 The use of mechanical profiling of concrete that has had curing compounds applied to it is considered the most effective way to remove the curing agents while creating a bond profile for the coatings to adhere to.

Diamond Grinding

This method uses various grit diamonds to grind the curing compound off.  Again, various bond profiles can be achieved with this method. 

Shot-Blasting

This method utilizes small metal beads that are “shot” at the concrete and then reclaimed through a high-powered vacuum system.  By utilizing different size beads, different profiles can be achieved.  Other methods of surface preparation such as acid-etching, light sanding, and power-washing are no longer considered acceptable.  These methods do not remove the curing agents applied to concrete in most cases. To conduct a basic field test to see if your concrete substrate is ready for a coating to be applied, place a few droplets of water on the surface.  If after a few minutes the water remains on the surface, adequate removal of the curing compounds has NOT been achieved.  However, if the water is absorbed into the concrete, the surface tension created by curing agents has been removed.   WHY EPOXY COATINGS FAIL Why Coatings Fail For any questions concerning Surface Prep, contact Thermal-Chem at 1-800-635-3773.

The Effects of Weather Variables When Installing Thermal-Chem Products

Installing Thermal-Chem’s portfolio of high-performance concrete coatings can be a very rewarding endeavor. With the expansion of custom colors, glow-in-the-dark flake, and a never-ending pallet with our DecoEssence metallic system, creating a one-of-a-kind floor is now easier than ever. There are however some environmental variables that need to be considered BEFORE the application begins.  Consideration of the project’s site conditions must be considered to ensure a successful application, so we will review these.

Screen Shot 2022 05 13 at 12.49.24 PMSlab Temperature

This is fairly straightforward.  Most of Thermal-Chem products are designed to be applied on substrates that are at least 50 Degrees F.  This is easily checked with an infrared digital thermometer. (shown left)

Material Temperature

When polymer products start to cure, they create heat or are considered exothermic.  Make sure that the project materials have had time to properly acclimatize to the slab temperature.  If you have just taken material from a hot work truck and bring into an environmentally controlled building, your material will have less working time. We recommend that you use the digital thermometer previously mentioned to obtain the material’s current temperature. weather.jpg

Ambient Air Temperature

Ambient temperature is quite simply the air on the project.  If the space is utilizing an HVAC system, a check of the thermostats will provide this information.  If not, you can use your smartphone and an app such as Weather Channel to get the approximate temperature in your area.

Relative Humidity/Dew Point

This reading is usually not considered by many installers but can be the reason for many problems.  Dew point is the temperature at which vapor condenses into liquid water.  It is a good practice to only install resinous coatings when the ambient (air) temperature is a minimum of FIVE Degrees F above the dew point during the application AND cure.  If the ambient reaches the dewpoint condensation will occur, thus leading to a whiteish finish or an oily film (amine blush) left on the surface of the coating.  The dew point is another reading you can obtain from your smartphone. The relative humidity is a measurement of the percentage of air that is occupied by water vapor.  If the relative humidity is 75%, this means the air is saturated with water.  Some coatings such as 100% solids are not nearly as affected by relative humidity as are water-borne coatings, and products with solvents in the formulation such as polyaspartic and polyurethanes.

Rule of Thumb: DO NOT apply a polymer coating when the dew point is within 5 Degrees F of the air temperature

Installing Thermal-Chem products can be a very rewarding endeavor, just make sure you understand the project conditions before beginning.

Floor coating contractors… it pays to ask questions!

It has been said that there are no dumb questions, only the ones not asked.  When visiting a new customer or an existing customer with a new project, it is extremely important to ask a lot of questions.

Attached is a nice sample survey that you can use or modify to gather the information you need to bid the project, a document that you can create a work ticket for your crew, and a permanent document for your client’s file. A fair number of flooring contractors are forgetting this important step.  Having this document in the future will allow you to speak to any questions or concerns your client may have.  Don’t let the excitement of the project steer you away from good business procedures.  This is one difference between a good contractor and a GREAT contractor. BE GREAT!

While not all of the questions on the survey will need to be answered, the ones that are answered will allow you to share precise project details, and in all likelihood, have your crew prepared to accomplish the project in the manner in which the customer is expecting. 

We’ve heard from several contractors; they brought in a questionnaire/survey and asked a battery of questions of the person showing them the project.  Our contractors are surprised when told by the prospect, “You were the only one to ask that many questions”.  Remember you need to find ways to stand out above your competition, let it start with the initial project review.

Time has taught us that “people don’t plan to fail, they fail to plan”.

New Job Inspection Survey

Inspection-SurveyScreen Shot 2022 02 03 at 8.56.38 AM 219x300 1

Copyright Thermal-Chem Corporation, 2026 - All Rights Reserved.
Call Us Now