Precast Form Coatings and Repair Materials

Precast form coatings are used by a range of industries to seal and protect surfaces and provide a smooth, long-lasting finish. At Copps Industries, we offer our Armorgard 505 series coatings for concrete, steel, wood, and foam forms. This product is capable of turning uneven or rough concrete forms into a level, smooth, and resilient surface. This not only extends the life of the surface but also enhances its overall quality.

Applications For Precast Concrete Forms

The many benefits of precast concrete forms make them ideal for a wide range of applications. For example, since these materials are non-flammable and VOC-free, they can be used in various application environments, both indoors and outdoors.

Common applications include:

Transforming rough and non-overlaid plywood and dimensional wood forms into level, smooth, and high-quality architectural forms
Creating a consistent surface for the application of form-applied surface-set retarders in exposed aggregate applications
Eliminating wood grain transfer and related concrete staining and discoloration in architectural concrete applications
Sealing plywood forms

Benefits of using Precast Form Coatings

Precast form coatings offer a host of advantages that make them desirable across several industries. Our Armorgard 505 series of coatings is a 100% solids, primerless, odorless, thixotropic epoxy coating that is specially formulated to produce a tough, hard coating without the use of hazardous or damaging solvents. Not only do our precast form coatings offer an extended working life, but they also result in high-quality casts suitable for various architectural applications.

Other benefits of precast form coatings include:

Solvent-free and VOC-free
Single coat application
Does not distort mold shape
Very tough, non-brittle surface
Low heat on cure
Seals hotwire cut foam patterns
Non-flammable
Repairable
Drill and cut without cracking
Eliminates the use of fiberglass cloth

How Long Will Epoxy Form Coating Last, How Can I Extend Their Life?

Precast form coatings are formulated to last for a long time, but there are steps you can take to ensure proper adhesion and longevity. These include:

Clean the substrate before application. To achieve optimal coating adhesion, it’s crucial to clean and remove any foreign or loose materials from the substrate. If any oils, greases, or other contaminants are present, adhesion will not be successful.
Ensure proper humidity and temperature. It’s important to determine the relative humidity and dew point before application to prevent adhesion problems. The dew point is used to predict the substrate temperature at which air starts to condense on the substrate. Never apply a coating unless the surface temperature is 5° F above the dew point. This difference in temperature must be maintained until the coating is cured to a tack-free state.
Avoid extreme temperatures. It’s important to note that epoxy form coatings will soften when exposed to extreme precast temperatures. To ensure the longevity of your coating, avoid those temperatures.
Proper storage. Epoxy forms coatings perform best when unmixed kits are stored at room temperature and are not exposed to subfreezing temperatures for exposed periods.

Process of Applying Epoxy Coating to Forms

To apply epoxy coatings to forms, follow these steps:

Prepare the Surface

Before application, any cracks or holes in the surface must be filled in and then sanded smooth. Once sanded, the form will need to be cleaned of all dust and oil.

Mixing

Measure the amount of Part A you wish to mix and pre-mix it for a minimum of 15-20 seconds to condition the product. After pre-mixing Part A, you can add your measured amount of Part B to the Part A and mix for three minutes. Mixing should be done at a speed where a slight vortex is formed with the paddle. Make sure to always keep the mixing paddle below the surface of the material to avoid the introduction of air bubbles.

Apply the Coating

Pour the material out in 4-inch ribbons on one side of the form. For even spreading, you can use aluminum notched rollers. It’s important to not overwork the material. Only roll it out enough times to get it off the roller. Continue this process down the form until the entire form is coated and complete.