Installation Instructions

Contents of the Major Metal Aluminum Oxide Grit Replacement Kit

• 2 quart can, Major Metal Aluminum Oxide Grit Replacement Kit Part A
• 1 quart can, Major Metal Aluminum Oxide Grit Replacement Kit Part B
• 1 bag, Major Metal Aluminum Oxide Grit Replacement Kit Grit mixture
• 1 drill bit, metal, for mixing the Major Metal Aluminum Oxide Grit Replacement Kit Epoxy Kit
• 1 plastic, aluminum rib cleaning tool
• Wooden stirring sticks

• Towels, for cleaning
• 4-gallon plastic mixing bucket

Additional Tools Required

• Drill, for mixing the Major Metal Aluminum Oxide Grit Replacement Kit Epoxy Kit
• Paint can opener
• Hand trowel, 5” square edge suggested
• Painter’s tape, 2” width minimum suggested
• Cleaning solvents, such as mineral spirits or acetone
• Surface cleaner, such as Simple Green

Preparation of aluminum pan for application of the Major Metal Aluminum Oxide Grit Replacement Kit - If the metal surface is greasy or oily, clean it with an appropriate degreasing product, such as Simple Green by following the instruction sheet for the safe and effective use of the cleaning product.

Test the surface for cleanliness before installing the Major Metal Aluminum Oxide Grit Replacement Kit. Apply water to the surface to be coated. If the water “beads up”, repeat the cleaning process. If the water smooths out and wets easily, the surface is ready. Always allow the wet surface to dry thoroughly before installing the Major Metal Aluminum Oxide Grit Replacement Kit.

Be sure to completely empty and clean treads before applying the Major Metal Aluminum Oxide Grit Replacement Kit. Partially filled treads can cause the incorporation of inclusions in the final, filled treads, which can cause early failure of the stair nosings. Use appropriate measures to break apart and remove any existing tread filling material prior to the use of the Major Metal Aluminum Oxide Grit Replacement Kit.

During the troweling process, there is a risk of getting the mixture onto the stair itself. To make clean-up easier, it is suggested to lay strips of painter’s tape (2” width or more) behind/along the nosing of the stair. This will allow, once the material has set, easy removal and cleaning of the edges of the nosing.

Mixing the Major Metal Aluminum Oxide Grit Replacement Kit - After removing all materials from the 4-gallon plastic mixing bucket, add the Major Metal Aluminum Oxide Grit Replacement Kit grit and the entire Epoxy Part A can contents to the 4-gallon plastic mixing bucket. One of the wooden stirring sticks should be used to scrape down the Epoxy Part A can to ensure all the material is removed from the can. The Epoxy Part A is viscous, and can easily stick to the inside of the can. Reserve the other stirring stick to scrape down the Epoxy Part B can.

Use the drill bit to mix the Major Metal Aluminum Oxide Grit Replacement Kit Grit and Epoxy Part A thoroughly (3–5 minutes). Use the wooden stirring stick to ensure dry aggregate is not stuck in the corners of the mixing bucket. The resulting mixture should be clumpy, and darker in color than the initial Major Metal Aluminum Oxide Grit Replacement Kit Grit mixture. Thorough mixing at this stage is required to ensure a consistent finished product.

Before continuing, ensure all preparations are ready to lay the Major Metal Aluminum Oxide Grit Replacement Kit. Once the Epoxy Part B is mixed into the Stair Saver Epoxy Kit, the curing process will start. This process is irreversible. The total working time of the mixture is 2 to 4 hours at 70 °F. The expected time necessary to apply a one gallon kit of the Major Metal Aluminum Oxide Grit Replacement Kit is 90 minutes. Warmer ambient temperatures will result in shorter cure times, cooler temperature may extend the working time of the mixture.

Add the entire Epoxy Part B can contents to the 4-gallon plastic mixing bucket. One of the wooden stirring sticks should be used to scrape down the Epoxy Part B can to ensure all the material is removed from the can. The Epoxy Part B is viscous, and can easily stick to the inside of the can. Use the drill bit to mix the kit thoroughly (3 to 5 minutes). The resulting mixture should be thick, smooth, and slightly darker in color than the earlier aggregate. The mixture will be sticky, and easily picked up by a trowel. Once mixed, the kit is ready for troweling into the empty aluminum pan. The drill bit can be cleaned with mineral spirits, and should be kept available to remix the kit, as necessary, during the application process.

Application of the Major Metal Aluminum Oxide Grit Replacement Kit - It is important to work deliberately at this stage. The Major Metal Aluminum Oxide Grit Replacement Kit mixture will begin to set as soon as the Epoxy Part B is mixed into the aggregate/Part A mixture. The mixture can be troweled into the aluminum pan in small scoops (roughly the size of a golf ball). The trowel is used to press the mixture into the aluminum pan. Apply pressure both along and perpendicular to the direction of the tread in order to ensure complete filling of the aluminum pan. The edge of the trowel can be used to remove/relocate excess aggregate by applying vertical pressure on the trowel and pulling across the aluminum pan. If the aggregate is dragging in the pan when troweling, use shorter, saw-like motions or work perpendicular to the tread direction.

Once completely filled, the ribs of the tread should be cleaned with the included aluminum rib cleaning tool. This plastic tool is designed to rest on the front edge of the aluminum pan, and the ribs are then cleaned by applying vertical pressure on the tool and dragging it along the direction of the aluminum pan. Small pockets of empty tread can be filled manually with small pieces of the aggregate mixture. This is most important near the ends of the aluminum pan, where troweling can be more difficult.

About once an hour, the kit should be remixed using the drill bit for about a minute, to assure the mixture is not separating. Failure to do this could cause the final product to have a glossy-like appearance.

Clean-up and Disposal of Major Metal Aluminum Oxide Grit Replacement Kit - The front edge of the aluminum pan should be wiped with a dry towel in order to remove any stray material. Once the Major Metal Aluminum Oxide Grit Replacement Kit material has fully set, any residue on the aluminum pan can be cleaned more aggressively with mineral spirits or acetone. The plastic, aluminum rib cleaning tool can be wiped dry with a towel; mineral spirts or acetone may damage this product. All tools should be cleaned of aggregate before it sets, as removal after the fact is significantly more difficult. Once all treads are filled, the remaining material in the Major Metal Aluminum Oxide Grit Replacement Kit should be allowed to fully cure before disposal. This should take less than 24 hours. In most locations, excess cured contents of the Major Metal Aluminum Oxide Grit Replacement Kit can be disposed of to a landfill, as the material is inert.