The following instructions are for applying resurfacer over new asphalt on one tennis court. If you are applying resurfacer to more than one court, it is a good idea to only attempt to coat one court at a time to start. After you and your crew feel comfortable with the process, you can take on as many courts as you like.
Prepare of 32 to 36 - 5 gallon pails of EviroFill Base Coat resurfacer mix. Mix each pail of coating thoroughly. Over time, the ingredients begin to separate slightly. The sand settles to the bottom and the lighter materials migrate to the top. Using a 1/2" electric drill and a paint mixing paddle stir each pail of mix until homogeneous. If you are using any of our concentrated products, read and follow the directions, on the label to the letter. View video on mixing Super Concentrate at this link: https://www.youtube.com/watch?v=nOBDd6X3_t4
You will usually make the first pour for your coat along the edge of one of the two back fences and squeegee the coat parallel to the baselines. The end at which you start is dictated by the best end to finish (i.e. the end having a gate you can use to squeegee out the court). Once you have determined the starting point and made your mix, place 6 pails along the starting fence line, and then 4 pails approximately every 20' until you have positioned all of the pails. You want all the pails strategically placed so that once you start squeegeeing, you will not have to stop until the coat is finished. The court will use up the resurfacer fast so make sure you have, at least, one helper to keep the row of coating replenished. It should never be allowed to run down to nothing. Make sure to leave the lids on (loosely). This will prevent a dry film or skin from drying at the top of the mix. It's also a good idea to replace the lids after each pailt is empty if you plan to keep them for future use. New five gallon pails cost around 6.00.
The pattern for sueegeeing the EnviroFill is quite simple: After pouring all 6 pails of EnviroFill along the starting fence line (approximately 6" from the fence), walk back and forth with your squeege from side fence to side fence, moving the row of coating approximately 6" each pass. Make sure that you squeegee the coating as close to the edge of the fences as possible. You will notice in the illustration that the person applying the coating turns the corner and pulls the coating 2 to 4 foot strip parallel to the side fence. In other words: think of your squeegee pattern as an upside down U.
Except where EnviroFill settles into the pores of the asphalt, the coating should go down very thin. Visualize a layer of fine sand spread out on the court only one grain thick and you have a good grasp of just how thin the coat of paint should be. If you see a puddle of coating or an unusually thick area, pass over it again with your squeegee. If the edge of your squeegee is cutting into the previous pass, leaving a ridge, make another pass over it with your blade out well beyond the ridge. If you are consistently getting these ridges, you are probably trying to take too much coating on each pass. Never let the coating pass beyond the middle of your squeegee blade as you pull the row.
As you squeegee, always try to keep your row of paint as straight as possible. Something we, in the industry, call "lap marks" will always be visible after the coating dries. Lap marks are actually the pattern you create with every pass of the squeegee. They look best when they are relatively straight.
Never just drop the blade of your squeegee down onto an area you have just painted. Unless you pass back over the spot rather quickly, you will leave an edge of paint called a "tool mark". Always start each pass just outside of the fresh coating and cut into it.
As you approach each of the areas where the pails are placed on the court, your row of coating will begin to run out. Always pour out more coating well before you run out. In the trade, we call this. "maintaining a wet edge". This is very important: DO NOT LET THE ROW OF COATING RUN DOWN TO NOTHING BEFORE YOU ADD MORE!!!!!! It is best to make your pours right on top of the row of coating on the court.
As you get close to the end of the court, try to estimate the amount of paint you will need to finish. If you pour an excessive amount onto the court, you will just have to shovel it up. When your paint row is about 10 feet from the finishing end, change directions and, in a swirling pattern squeegee towards the exit gate (or other exit point such as an opening in the corner of the fence.
Squeegee the remaining small amount of paint into a puddle on the court, just before the exit point, scoop it into an empty 5 gallon pail with a flat shovel and squeeee the last, small amount off of the court as you coat the remaining area. If you have been careful to shovel up as much paint as possible you will squeegee very little coating over the edge of the court. If you still have more than a pint left on the court carefully scoop it up and put it in a pail. If this leftover paint is contaminated with a lot of debris (leaves, scrapings, etc...), do not try to recycle it, as is, into the next mix. Screen it through a piece of steel hardware fabric with 1/8" grid, before recycling it, or dispose of it.
Most courts will only need one coat of EnviroFill. However, if you can still see the aggregate in the asphalt, or your patch work or other imperfections are still visible, a second coat might be in order.
Do not apply a second coat of EnviroFill or any other coating for 24 hours.