The Professional Epoxy Flooring Process

Phase 1: Meticulous Surface Preparation (The Foundation of Quality)

This is the most critical phase, determining adhesion and longevity.

1. Moisture and Contaminant Check: The concrete slab is tested for moisture vapor transmission (MVT), as excess moisture will cause the epoxy to bubble or delaminate. The surface is also inspected for existing coatings, sealers, oil, and grease.

2. Mechanical Surface Profiling: Unlike DIY methods that use acid etching, professional application requires mechanical abrasion (shot blasting or diamond grinding). This process:

   • Removes old coatings, sealers, and contaminants.

   • Creates a rough, porous texture, known as the Concrete Surface Profile (CSP), which is essential for the epoxy to bond permanently with the concrete.

3. Repair and Patching: All cracks, pits, expansion joints, and surface spalls are repaired using specialized epoxy fillers and crack repair materials. This ensures a completely smooth and sound canvas.

4. Cleaning and Vacuuming: The entire area is vacuumed with a HEPA filter vacuum to remove all fine concrete dust and debris created during grinding, ensuring the surface is perfectly clean and dust-free.

Phase 2: Primer and Base Coat Application

This phase establishes the system's foundational layers.

1. Primer Application (Crucial for Adhesion): A penetrating epoxy primer is mixed and applied. The primer soaks into the concrete, sealing the pores and creating the strongest possible bond between the substrate and the subsequent epoxy layers. It also helps prevent outgassing and bubbles.

2. Base Coat Application: Once the primer is cured, the tinted epoxy resin (the base coat) and its hardener are accurately measured and mixed. This material is immediately poured onto the floor, spread with a notched squeegee, and back-rolled to achieve a uniform thickness.

3. Flake/Aggregate Broadcasting (Optional): If a flake system (full or partial broadcast) or an anti-slip aggregate is required, the chosen material is broadcast (thrown) evenly over the wet base coat until the surface is saturated. This step must be completed quickly before the base coat begins to cure.

Phase 3: Scraping, Cleanup, and Top Coat

The final phase seals the system and prepares it for service.

1. Scraping and Vacuuming (Flake Systems): After the base coat and flakes have cured, the excess, non-embedded flakes are scraped off the surface. The area is then thoroughly vacuumed again to remove all loose material, ensuring a smooth finish for the topcoat.

2. Final Topcoat Application: The transparent, high-performance polyurethane or polyaspartic topcoat is mixed and applied. This clear layer seals the flakes and the base coat, providing the system's final defense against UV rays, chemicals, abrasion, and heavy traffic. This coat is applied to the manufacturer's precise thickness specifications.

3. Curing and Return to Service: The installation area is secured to prevent traffic.

   • Foot Traffic: Typically allowed within 24−48 hours.

   • Heavy Traffic/Chemical Exposure (Full Cure): The floor requires a full 5−7 day cure time to achieve maximum chemical and mechanical resistance before being returned to full commercial or industrial service.