POLYSTABLE®
POLYSTABLE® FLOORING SOLUTION WITH ANIMAL WELL BEING IN MIND
The PolyStable Kit Flooring System has been developed to provide a comfortable, durable and water tight flooring solution for animal stabling areas. This increases the animals well being due to the natural cushioning and insulation properties of the flooring system. This reduces consumption of bedding materials required, giving both a cost saving and a reduction of waste removal from the bedding area.
The tough, durable top finish is more aesthetically pleasing than stable matting but with an inherent “give” reducing impact on any livestock’s hooves. The PolyStable Kit system features a built-in wear indicator giving the stable owner extra confidence in the floorings integrity.
INSTALLATION METHOD STATEMENT
POLYSTABLE® installation is a four stage process which can be completed in a day on an average sized horse stable (typically 16 m2).
PREPARATION
Before starting to install the PolyStable Kit Flooring System ensure you have all the tools you need for the job at hand and that you have enough product to complete the area. Cover the ground area with a suitable ground sheet to prevent unwanted transfer of resin on the central flooring. Have your mixing station close to the work area and again, work on top of ground sheeting. Also ensure that you have a suitable cleaning solvent (for example PolySolv) ready for when you have finished the installa- tion. Read both the Product Information and Safety Data Sheets for all materials prior to any application.
The PolyStable Kit System can be installed onto most concrete, stone or tiled flooring surfaces. Clean out and power-wash the area to be surfaced, then allow to dry. A hot air blower can be used which will warm the surface and aid the curing process for stage 2. For particularly porous surfaces apply a coat of Poly Primer to aid the bonding of the SBR layer. Ensure the surface is relatively even by filling any large cavities. Depending on the depth of the SBR layer, most minor irregularities in evenness will be covered without being rectified. Typically, a stable area will be fully enclosed so it will be unnecessary to baton the area.
| POLYSTABLE (ST) SPREADING RATES (per 16 m² stable) | ||||||
|---|---|---|---|---|---|---|
| Component | Description | Quantity | Instructions | Workable Time* | Curing Time* | |
| Base | POLY QS30 Binder | 20% of SBR | 3 x 25 kg | 60 mins | 90 mins | |
| Aliphatic Activator 0613 | 3% of Binder | 2.25 kg | Mix Binder and Activator thoroughly | |||
| Black SBR 1-4 mm | 40 mm depth | 15 x 25 kg | Mix Binder and Activator thoroughly | |||
| Sealer | PolyStable Sealer | Part A & B 3:1 ratio | 4 x Kits | Mix with rubberised dust | 30 mins | 3-4 hrs |
| 20% dust | 4.8 kg | Squeegee across surface filling all voids. Scrap off excess. |
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| Top 1st Coat | PolyStable Top Coat | Part A & B 4:1 ratio | 2 x Kit | Roller on to top | 25-30 mins | 2 hrs |
| Top 2st Coat | PolyStable Top Coat | Part A & B 4:1 ratio | 2 x Kit | Roller on to top | 25-30 mins | 2 hrs |
Base Layer
Load a forced action mixer with either 1, 2 or 4 bags of base SBR, depending on the mixer size. Weight out the required polyurethane binder (5 kg for a 1 bag mix, 10 kg for a 2 bag mix, 20 kg for a 4 bag mix) and add 3 % w/w Activator then mix thoroughly. Less Activator can be used in particularly hot and humid conditions. Add the activated binder to the SBR in the mixer then mix, ensuring that all the rubber is thoroughly coated. Starting at the edge furthest away from the stable entrance, work the resin bound SBR into the area being surfaced, ensure it is well-compacted, and level off to the required depth, typically 40 mm.
Do not walk on the rubber base until the material has set, which is normally after approximately 90 minutes at 20°C. Weather conditions can have quite a substantial effect on the curing times. Allow extra time for curing if installing the base on a cold, dry day as where on a hot damp day the base will cure a lot quicker, the working time of the resin bound SBR mix will be reduced.
When the rubber base is laid in the stable and curing, leave any doors or gateways open to allow as much air circulation as possible. If necessary, bar access to the stable with an open mesh webbing.
Base Layer – SBR 1-4 mm bound together with Polytech QS30 Binder (with 3 % w/w activator)
SEALING LAYER
Empty the smaller part B of the PolyStable Sealer Kit into the larger Part A PolyStable Sealer Kit bucket and, using a mechanical mixer, combine the two parts. Ensure that the resin is thoroughly mixed. Blend in the rubberised dust (1.2 kg per kit). Only mix one kit at a time, mixing the second kit after the first kit has been used and so on. Four kits will be required to complete a 16 m2 stable. Using a screeding trowel, work sealer resin into the SBR base layer surface, filling all voids. Work from the furthest edge of the stable toward the stable door and scrape off any excess resin / dust mixture as you go. When finished the surface should be quite even with the black SBR surface just visible beneath the resin / dust layer. Leave any doors or gateways open to allow as much air circulation as possible while curing. If necessary, bar access to the stable with an open mesh webbing.
At the point when the sealer no longer transfers off the surface, it is ready to accept the PolyStable Topcoat layer of the system. This can be tested with a gloved hand. The sealed surface will retain some tack but should not stick when walked upon.
Sealing Layer
TOP COAT
Empty the smaller part B of the PolyStable Topcoat Kit into the larger Part A PolyStable Top Coat Kit bucket and, using a mechanical mixer, combine the two parts. Ensure that the resin is thoroughly mixed. Only mix one kit at a time, mixing the second kit once the first has been used; two kits should be sufficient to cover the entire stable. Transfer the combined resin to a roller tray and apply to the floor from this tray with a roller. Do not pour directly onto the floor and roller out. For this first coat of two, work from the stable door toward the furthest edge of the stable. For this coat boot covers should be worn and the area outside the stable entrance covered to prevent resin being transferred to other areas. Leave any doors or gateways open to allow as much air circulation as possible while curing. If necessary, bar access to the stable with an open mesh webbing.
At the point when the resin no longer transfers off the surface it is ready to accept the second layer of topcoat. Empty the smaller part B of the PolyStable Topcoat Kit into the larger Part A PolyStable Top Coat Kit bucket and, using a mechanical mixer, combine the two parts. Ensure that the resin is thoroughly mixed. Only mix one kit at a time, mixing the second kit once the first has been used; two kits should be sufficient to cover the entire stable. Transfer the combined resin to a roller tray and apply to the floor from this tray with a roller. Do not pour directly onto the floor and roller out. For this second coat of two, work from the furthest edge of the stable toward the stable door. Again, leave any doors or gateways open to allow as much air circulation as possible while curing. If necessary, bar access to the stable with an open mesh webbing.
Under typical conditions the top layer should cure to touch in about 2 hours. It will take 7 days to reach complete cure and the stable should not be used during this time.
1st Topcoat
2nd Topcoat and Final POLYSTABLE product
PLIXXENT IS YOUR PARTNER FOR INNOVATIVE PU SOLUTIONS
As a flexible company, PLIXXENT develops polyurethane systems that meet your needs. With the purchase of PURE-FLEX® in 2021 we added 50 years of experience in developing and producing polyurethane adhesives to our port- folio to offer producers of flexible packaging worldwide high quality solutions for their needs.
For more information on Polytech Liquid Polymers POLYSTABLE systems please call: +44 1625 575737