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School Bus Floor - Many Questions


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Greetings! Many questions so please bear with me.

We'll be using KBS to coat the partially-rusted interior floor (galvanized) of a school bus. We also wish to use KBS & fiberglass mesh to seal bolt / screw holes in the floor.

1) I've read 1 gallon is good for 2 coats & 200 sq ft. Is this correct? We plan on 4 coats, so for our 150 sq ft, I figured 1.5 gallons would be about right.

2) We have many old bolt/screw holes to fill using fiberglass mesh. Smaller holes ~2mm diameter, larger holes ~10mm. Would you recommend we lay down the fiberglass on first coating and then just lay down successive coats as usual, or should we patch and coat the holes as a separate step entirely? If as a separate step, would it be better to patch holes first, or coat first?

3) Because it's a bus, I hope apply most of the kbs with a roller. is this OK, and if so, what composition & nap of roller should I use?

4) Because it's a bus, it's going to be difficult if not impossible to lay down 2nd+ coats w/o walking on prior work. Assuming clean feet (painters booties) will this damage the prior coat? Or should I do 1/2 the bus, wait for full cure, and then the other?

5) We've already ospho'd the floor about a month ago after a vigorous cleaning & wire brushing. Your instructions say to clean/degrease the surface first, then use your brand of rust converter, and rinse. Would it hurt if I reversed the steps? For example, I was planning to 1) re-wet the floor with ospho and scrub, 2) rinse thoroughly with clean water, 3) knock the whole thing down again w/ 80 DA, 4) use your cleaner / degreaser, 5) rinse again, & dry thoroughly, and then 6) apply KBS. Will this work?

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1) Yes, a RustSeal gallon typically covers 200 sq ft with 2 coat coverage. Yes, for 150 sq ft and 4 coats, 1.5 gallons should be the correct amount.

2) Yes, lay down the BackBone Mesh in the first coat of RustSeal and then apply additional coats of RustSeal over it using the correct time frame between coats.

3) A low nap foam roller is best. Thin RustSeal 10% with KBS #1 Thinner when rolling.

4) Yes, you can walk on the previous coat of RustSeal with painters booties. That is no problem at all. People do large concrete floors all of the time and do exactly this.

5) Yes, that should be fine. Please make sure the surface is bone dry before applying RustSeal.

We want your project to be a complete success so please be sure to read through carefully the following documents which will ensure your success using KBS Coatings.
RustSeal Directions: https://www.kbs-coatings.com/rustseal-directions.html
RustSeal: https://www.kbs-coatings.com/RustSeal.html
RustSeal Kits: https://www.kbs-coatings.com/stop-rust-paints.html
RustSeal Application Videos: https://www.kbs-coatings.com/instructional-videos.html
RustSeal Flow Chart: https://www.kbs-coatings.com/rustseal-flow-chart.html
RustSeal How-To Section: https://www.kbs-coatings.com/how-to-use-kbs-coatings.html
RustSeal Fix-It Guide: https://www.kbs-coatings.com/fix-it-guide-rustseal.html

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