ZIRCONIA CERAMIC COATINGS

Biosecurity is the act of preventing the spread of microorganisms (viruses, bacteria, fungi, and more) to animals and humans, which can be transmitted through surfaces, food, water, air, and soil. Structural biosecurity is the building, engineering, and design controls that assist in this prevention. Zirconia has revolutionized structural biosecurity through new surface coating technology that transforms surfaces and structures to be Biologically Impervious™ to all microorganisms.

Just as humans and animals, microorganisms need habitat, moisture, and food (nutrients) to survive and grow. Microbes are a little more complex and need specific ranges of pH, temperature, and oxygen as well, but if any one of the main needs of habitat, water, and food are eliminated, microbes cannot survive and grow.

When it comes to infrastructure building materials, the supply of food and moisture to microbes is inextricably linked through habitat in the building material itself. This is true for any material, such as concrete, steel, stainless steel, wood, PVC, and more. All of these materials are either grossly porous (wood, concrete) or microporous (stainless steel, PVC), trapping food and nutrients for microbes that contaminate those ready habitats.

Until now, there have been imperfect modern designs for preventing microbe contamination. For example, materials such as stainless steel and PVC are used in food manufacturing since they were designed to be less porous and easier to clean. Though these materials meet the governmental standard of non-porous, there are micro-pores in both of these materials that are large enough for microbes to live in. For concrete, there are epoxy and urethane coatings to prevent degradation. However, these coatings can only form a physical bond with the textured surface, and these fail by peeling, cracking, and allowing moisture to seep in from underneath the concrete. Due to the inevitable failure of all these designs, there are harsh chemicals and cost/time-intensive cleaning protocols to eliminate microbes.

Biologically Impervious™ refers to surface systems that are engineered with very specific characteristics to perpetually prevent the survival of microbes within and on infrastructure surfaces, which can destroy building materials as well as cross-contaminate food, water, animals, and humans.
All Zirconia systems include the following three characteristics and properties that make them Biologically Impervious™: non-porous, easily cleanable, active antimicrobial layers.
Non-porous: unlike any other surface coating, Zirconia’s ceramic surface technologies chemically bond with the surface and fills in all gross and microscopic pores. Pores are filled down to the single nanometer measurement, leaving nanopores so small that even the smallest microbe cannot penetrate, also blocking out moisture and nutrients needed for microbe survival. Compare this image of concrete treated with Zirconia’s CeramycShield with the porous raw concrete image above. (Insert image “Eliminates. Voids”)
Cleanable: due to the virtual elimination of all pores, and the combination of ceramic surface technology with urethane and other coating sealants (such as Zirconia’s ComposiCoat™ Floor Finish system), surfaces are so smooth that they are cleanable with just water. Because any cross-contamination of microbes would be limited to the surface only and without penetration into the surface material (through cracks, fissures, and pores as in non-treated surfaces), cleaning is less time and material intensive, and the use of harsh chemicals can be virtually eliminated (depending on the industrial use of the surface).
Active Antimicrobial Protection: All Zirconia coating systems employ some form of one or a combination of multiple antimicrobial mechanisms. The different types of antimicrobial actions can come through several different forms:
⦁ Bi-metallic surface using safe alumina-zirconia-silicate polymers that naturally oxidize and destabilizes microbe cell membranes (similar to the action of copper, silver, and platinum). This layer also prevents biofilm from forming on the surface.
⦁ The photocatalytic surface increases oxidation with UV light but will not break down with high UV exposure.
⦁ Antimicrobial additives mixed with the coatings in liquid form survive the drying process to provide continuous disinfectant action.
⦁ Nanosword surface technology that before Zirconia’s technologies provided only temporary antimicrobial action. Nanoswords include a carbon “sword” chain that projects from the surface to physically break apart microbe cell membranes. Zirconia’s surface coatings provide a more permanent bond with the nano sword technology for a long-lasting antimicrobial effect.

Zirconia’s surface coating systems can have up to 4 layers of antimicrobial systems or mechanisms to protect the surfaces and environment. For example, the CeramycGuard/QuartzSeal coating system has a 4-layer defense, as shown. This system provides multiple layers of microbial defense both from above and below. BioSec will be glad to discuss our systems with you if you have any questions.

Zirconia is not a one trick pony when it comes to its approach to green technology and working to improve sustainability. Zirconia is always working with the environment in mind and we have a number of ways that we are making an impact.

1. Preserving Old & New Infrastructure Indefinitely

Zirconia’s technologies create multiple paths to large scale greenhouse gases (GHG) reduction. Future technology development also looks promising.
Using Zirconia’s ceramic sealants to increase the durability of concrete and steel used to build major infrastructure represents a huge savings in greenhouse gases both near term and long term, because our advanced ceramic technology can repair, and restore existing infrastructure, and also dramatically increase the lifespan of new infrastructure.

What does this mean? Basically, Zirconia eliminates the “run-to-failure” construction/maintenance model that allows existing infrastructure elements to decay to the point of collapse, then requires re-digging of raw materials, reprocessing them, and remaking concrete and steel elements.
Concrete and steel are two of the largest sources of greenhouse gas emissions globally, roughly 18%. Any infrastructure asset (e.g., bridge, dam, etc.) built with concrete and steel is “GHG expensive”. So, saving these assets from decay and eliminating the need to remake them, saves enormous volumes of toxic greenhouse gas emissions.

What is the key takeaway? Most corrosion (chemical erosion) occurs at the surface of concrete and steel and works inward as the asset decays. If the surface of infrastructure assets is coated with Zirconia technology, the surface chemistry of concrete or steel is stabilized and preserved (no corrosion), and the entire asset is then preserved indefinitely.

2. Reducing Toxicity to the Environment

As a clean-tech company Zirconia is always pushing the boundaries of green chemistry to make our coatings and other technologies less toxic, while keeping all the best performance characteristics.

For instance, our CeramycGuard technology is water borne, not solvent borne, meaning it does not expose workers or the environment to toxic solvents. This is a huge advantage for “inorganic” chemistries like ours that can be suspended with water, where organic chemistries cannot be.

3. The Power of Substitution:

As we enter the market, we are replacing old toxic technologies like providing the type of products that can reinvent the construction industry by substitution of coatings and other products that both perform better and are much less toxic than previous products. We are also finding ways to make other multi-layer coating systems, like urethanes, less toxic and far more durable, reducing their impact.

4. Reducing Toxicity to the Employees and Workers

Organic coatings have different types of toxicity. Some organic coatings are held in solution by toxic volatile organic compounds (VOCs) that evaporate as the coating cures. These VOCs can be damaging to human organs, and/or be carcinogenic. Epoxies use Bisphenol A which is a hormone disruptor (endocrine disruptor) and can damage the development of children. Polyurethanes can be immune system sensitizers, creating anaphylactic shock and even death when exposed repeatedly.

As an industrial society, we need coatings to prevent decay and extend lifespan of our infrastructure, and other assets like ships and cars. However, we should consider using the least toxic technology possible, with worker health in mind. Zirconia is always looking for the green chemistry pathway to provide similar or better coating performance and durability, without the need for hazardous materials.

5. Looking at the future...

Our various ceramic technologies and know-how will allow us to continually create new technology to adapt the built environment to climate change, and preserve the environment we all share.

A. CoolColors™ Our coating technology has a 98% Solar Reflective Index, meaning it stops buildings from absorbing infrared energy from the sun and heating up. Using CoolColorTM ceramic coatings to increase reflectivity (heat deflection) and emissivity (heat dissipation), will cool buildings way down and reduce the need for electricity draw for air conditioning significantly, reducing the need to burn fossil fuels, and therefore reducing CO2 emissions significantly. This technology has already been fully developed, and we are looking to release this technology in 2022.

B. Future development: Our ceramic technology has very appealing properties for creating new forms of cellular ceramic insulation that could be used to retrofit commercial buildings and equipment. Our tech is immune to microbial growth, thermal changes (heat/cold), weathering and corrosion. It will also both absorb and deflect sound. And, these new forms of insulation could be used to clad buildings from the outside in, potentially appearing like artificial brick or stone, eliminating the need to demolish and rebuild walls, thus reducing the cost of renovation.

Some Practical Challenges

Concrete is one of the most popular and heavily used building materials in the world, and it has many great characteristics. It is strong, durable, plastic, and versatile. However, it has some challenges as well. Concrete is porous and chemically unstable, which means that for most applications, for concrete to meet its full potential, it needs a coating to reduce porosity and protect it from chemical and water attack.

Some Common Problems

The problem is traditional coatings don’t work. Epoxies, urethanes, and other “organic” or plastic coatings do not bond to the concrete but rely on the tooth or profile to adhere to the concrete. This requires a lot of preparation, and they can easily delaminate. Everyone has seen coatings peel from concrete, and it is a common problem.

Some Common Problems

Zirconia has a new solution. Zirconia protects concrete from corrosion by utilizing our Ceramic Sealant technology, the first ceramic-polymer coating that chemically bonds to these surfaces and protects them indefinitely. Moisture and temperature cannot cause this coating to delaminate or peel because it is chemically formed a new composite layer at the concrete’s surface that is durable and non-permeable. By making the surface chemically stable and reducing porosity, the life expectancy of concrete structures can be greatly increased.

We offer CeramycGuard as a base coat to several systems to provide the surfaces needed for a variety of commercial applications.

Zirconia’s CeramycGuard™ is a concrete surface coating that uses nano-Alumina and Zirconia Silicates to renew and preserve concrete surfaces. This new technology inhibits attack from water, chlorides, carbonation, biological infection, and sulfates that are the main causes of concrete decay. Zirconia has the same kill mechanisms as copper and silver. The CeramycGuard system is UV reactive which causes H20 at the surface to convert into oxides like hydrogen peroxide(H2H2) and killing surface pathogens. A LEED 4.2 compliant material, CeramycGuard provides superior performance properties while maintaining ease of application properties.

⦁ Penetrating Chemical Adhesion
⦁ UV Immune
⦁ Pathogen resistance
⦁ Will Not Chalk, Peel, or Disbond
⦁ Biologically Impervious®

⦁ Clean/Dirty Entry’s
⦁ Showers
⦁ Office
⦁ Slats – Precast
⦁ Walkways (floor & walls)
⦁ Animal Load Chute (floor & walls)
⦁ D&D, Receiving
⦁ Laundry
⦁ Cistern Tanks
⦁ Kitchen/Break Rooms
⦁ Sidewalks
⦁ Truck Wash Bays
⦁ Feed Mills
⦁ Loading Docks
⦁ Wastewater Treatment
⦁ Greenhouses (floor & walls)
⦁ Commercial & Industrial Floors
⦁ Food Storage & Processing
⦁ Meat Processing
⦁ Dairy Parlor
⦁ Animal Husbandry
⦁ Live Animal Production

ComposiCoat™ Floor Finish

What is ComposiCoat?

A three-layer system that chemically bonds to concrete for exceptional chemical, abrasion, and microbial resistant protection.

Concrete is a porous and chemically unstable surface that is highly reactive with multiple chemicals and unstable due to the constant exchange with water and moisture. Traditional coatings like epoxies, urethanes, and paints attempt to control this instability by a non-permanent barrier layer on top of the concrete. These coatings are traditionally organic plastics that are unable to chemically react with the concrete and can only stick or grab onto the surface texture to stay in place. These coatings quickly degrade and peel off due to their weakness when exposed to UV sunlight and the inability to breathe out trapped water vapor. Trapped moisture in the concrete allows for carbonation, and biological growth, leading to corrosion, cracking, spalling, rebar rusting, and eventual concrete failure.

The solution is to use a system that combines the best of the inorganic properties of concrete and geopolymers with the best characteristics of organic or polymer coatings. Zirconia’s CeramycGuard is an inorganic ceramic base coat that chemically bonds to the concrete giving a permanent crosslinked base for the system. This base coat is impervious to vapor pressure and cannot delaminate, peel or come off the concrete from moisture movement. It is also harder than the concrete itself, giving durable, long-lasting protection. The top layers over the CeramycGuard add the benefits of organic/plastic coatings, having great resistance to chemicals and abrasive wear. Since they are chemically crosslinked to the inorganic ceramic base coat, they cannot fail from high moisture levels and will not peel as they are not individual layers but a composite of organic and inorganic chemistries.

Part 1: CeramycGuard™, the base layer, is an inorganic ceramic polymer that chemically crosslinks into the concrete surface, forming an ultra-durable ceramic composite. Part 2: CrossLinker™ VB is a hybrid compatibilizer-primer and vapor barrier which crosslinks the base ceramic composite to Part 3: ComposiCoat™ XD topcoat. The topcoat is chemical and abrasion resistant, easy to clean with biologically impervious properties. Once cured, all three layers are chemically bonded permanently into the ComposiCoat Floor Finish system. This composite flooring system has all the durability benefits of advanced ceramics and plastics technology, taking advantage of the best characteristics of both organic and inorganic coatings.
ComposiCoat™ Floor Finish
Product Description
With the ComposiCoat Floor Finish system, chemically unstable concrete is replaced by an ultra-stable ceramic-urethane composite, protecting it from chemical and physical erosion. This unique flooring system is also Biologically Impervious®, meaning it is designed to eliminate microbial habitat and continuously prevents microbial invasion and growth.

⦁ Easy to clean, non-yellowing, UV stable
⦁ Biologically impervious, preventing invasion and degradation by microbes
⦁ Superior abrasion resistance and durability
⦁ Chemically resistant to many types of acids, fuels, ammonia hydroxide, and many others (see ComposiCoat XD product data sheet for a full listing)
⦁ High solids, no odor, safe for indoor and outdoor use
⦁ VOC compliant Industrial Maintenance Coatings of North America
⦁ Tru-Composite® system that is resistant to subsurface concrete moisture

⦁ Farming, agriculture, dairy, livestock
⦁ Food production, manufacturing facilities, and storage rooms
⦁ Commercial flooring such as loading docks, distribution centers, parking ramps
⦁ Surgery/sterile rooms, waiting rooms, locker areas, exercise facilities, laboratories

Zirconia’s CrossLink VB is the catalyst/crosslinking agent that bonds the CeramycGuard surface treatment and the ComposiCoat XD urethane finish together to form the 3-part composite flooring system. CrossLink VB creates a complete moisture barrier that will not chalk, peel, or delaminate and creates a strong adhesion promotor for CompsiCoat XD.

Zirconia’s Ceramic System Accelerator™ (CSA) uses colloidal silica technology to provide an optimal surface for application of Zirconia’s Ceramic Surface Treatments. When applied at time of placement, it allows CeramycShield to be applied in 5-7 days as opposed to waiting 28 days for traditional coatings. CSA penetrates deeply into the accessible capillary system, reacting with the available free alkali, forming additional calcium silicate hydrate (C-S-H). The treated concrete performs comparably to moisture cured concrete with reduced permeability, denser surface reduced drying shrinkage. This means that no curing agents need to be used or removed prior to applying coatings.

CSA and CeramycGuard can be used as the system of choice, part of an overall system for waterproofing above grade concrete and CMU where elastomeric systems are not required. CSA along with Zirconia’s Ceramic Surface Treatments provides permanent concrete protection while also providing improved conditions for concrete performance.

Zirconia’s Ceramic System Pore Blocker™ (CSPB) uses colloidal silica technology to provide an optimal surface for application of Zirconia’s Ceramic Surface Treatments. One of the benefits of CSPB is that on existing concrete it will either purge or encapsulate contaminants in the concrete while providing more CSH for CeramycShield™ bonding. Colloidal Silica technology penetrates deeply into the accessible capillary system, reacting with the available free alkali, primarily forming calcium silicate hydrate (C-SH). The surface becomes a denser harder surface for durability.

ComposiCoat™ XD Floor Finish is the ideal choice for chemical and abrasion resistant applications, with biologically impervious properties that reduce the growth of microorganisms. The aliphatic moisture cured urethane can be applied with satin or high gloss finishes in clear or colored tint options for aesthetic preferences. Zirconia’s

ComposiCoat™ Flooring System provides exceptional wear protection from abrasion, chemicals and solvents and is easy to clean and maintain. When used with Zirconia’s CeramyGuard™ coating as a base coat you have a composite flooring system that has an inorganic, base that chemically reacts or “cross-links” with the concrete. Adding Zirconia’s CrossLinker VB™ as a primer for ComposiCoat™ XD it creates a cross- linked connection with the urethane final coat. This means you have created a composite flooring that takes advantage of the best characteristics of both inorganic and organic coatings.

ComposiCoat Floor Finish is an excellent choice for protecting and preserving concrete surfaces in commercial, industrial, and institutional applications including but not limited to:

Commercial: manufacturing, distribution, hangars, maintenance areas, parking garages, loading docks, and heavy traffic areas Food: processing, manufacturing, and cold storage Farming: agriculture, dairy, livestock Health Care: waiting rooms, surgery rooms, laboratories, and bathroom floors Health and Fitness: gym and exercise facilities, and locker rooms

Zirconia QuartzSeal™ is penetrating, chemically bonded, inorganic sealant that when applied over CeramycGuard™ further inhibits water, chemical pollutants and the “near zero porosity” inorganic glass layer finish helps seal out dust, dirt and protects against stains. Rising to the surface of QuartzSeal™ is a dense layer of electrostatically charged nano-swords that prevent microbial occupation and create a Biological Impervious*, super clean surface.

Parking Garages (Walls)
Precast Products (Slabs, Pipes)
Cinderblock Walls
Bridges (Beams, Piers/abutments)
Seawalls & Wharfs
Dams
Storm Drains
Tanks
Tunnels
Wastewater Treatment
Water Treatment
Greenhouses (Walls and Floors)
Retaining and Sound Barrier Walls