Types of Epoxy Flooring and Epoxy Installation Process

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Epoxy flooring materials are becoming increasingly popular in commercial as well as industrial use. Epoxy flooring comprises a two-section epoxy system- a blend of polymer resins and hardeners, similar to an epoxy glue. These organic carbon chain compounds mixed with other elements like hydrogen, oxygen, and nitrogen look extremely incredible, along with lifetime advantages. 

 

The epoxy flooring is of different types which are used on floors. Some types are self-leveling epoxy coatings, self-dispersing epoxy, graveled, mortar epoxy, antistatic epoxy, and vapor barrier epoxy. Each of these has distinctive advantages. 

Advantages of Epoxy Flooring:

• Epoxy creates a shiny gloss surface. 
• It offers a hard, durable surface able to withstand heavy traffic and vehicle movement. 
• Quick and easy installation process. 
• It requires the least installation equipment, adhesive, and layouts.
• Ideal for commercial and industrial applications 
• Resistant to oil stains, watermarks, and scratches. 
• It helps create a smooth high-end texture on a surface that lasts lifelong. 

Types of Epoxy 

 

1. Self-Leveling Epoxy Coating: These are easy to use and install over new and old concrete floors. These types of epoxy are best to level the floor and create a seamless and smooth surface. Self-leveling epoxy coating can be used in storage places, garages, kitchens, dining rooms, office buildings, etc., 





2. Self-Dispersing Epoxy: This type of epoxy is commonly used in areas prone to frequent movement of vehicles or trucks as this epoxy has great mechanical strength. It is durable and commonly noticeable in food processing industries, logistics movement, or liquids, as this epoxy also has anti-slip characteristics. 





3. Graveled Epoxy: Graveled Epoxy coatings are the most decorative epoxy flooring choice as they are easily customizable according to customer’s needs. Brands often use this type of epoxy to add branding marks, decorative details, and logos on the floors. 





4. Flake Epoxy: Flake Epoxy is a style of applying an epoxy coating. With this technique, professional epoxy flooring painters can create multi-colored flakes or chips added to the epoxy mixture to achieve a flaky look. 

Step by Step Instruction for Epoxy Flooring Process

 

Step 1: Cleaning the Surface 

The intended surface should be spotless. You can begin the floor cleaning process with a leaf blower to get rid of the wood chips, dirt, or anything that’s sitting on the surface. 

 

Note- When you blow all the floor dust, ensure to use the leaf blower on the walls as well. 

 

Step 2: Inspect the Floors for any residue. 

Believe it or not, the worst happens when we least expect it. To avoid falling into the worst case, you should ensure a final inspection of the floor before installing the epoxy. If there is any paint drip on the floor, you can use Soy Gel or a paint stripper to lift the paint. 

 

Step 3: Sanding the Floor and Vacuuming

Sanding will help balance out the rough concrete edges and flatten your floors smoothly. You can hit the floors with a sanding screen at 60 or 80 grits two times perpendicular to each other. Now, remember that sanding will create a lot of dust. For that, you can apply water and then vacuum it all up. 

 

Step 4: Acetate 

Mix one to one ratio Water with Muriatic Acid and apply with a sprayer. In circular motion. The circular motion spraying will prevent getting patterns on your concrete and give you better coverage on that concrete. 

 

Step 5: Neutralize the Acid 

Use Ammonia and Water mixture in the ratio of 20:1. You can use a commercial scrubber to spread the water and ammonia mixture, or you can throw the mixture with a cup on the entire floor. Make sure to spread the mixture using a stiff-bristled broom and vacuum it next. Don’t leave anything undone. Cover everything.   

 

Step 6: Cleaning up Ammonia 

After neutralizing the acid, give the floor one more rinse with clean water. Now in a way, you need to clean up the Ammonia. Give the floor one pass or maybe two until it is clean. The vacuum will absorb water from the pores of the floor. 

 

Note: Use the commercial vacuum. Just moping or wiping is just like gliding over the floor. 

 

Step 7: Let the floor dry.

After absorbing the water all day, your floor will end up with a high moisture level. Thus, it would help if you made sure the floor is entirely dry. Leave it dry completely overnight. The moisture level in the floor should be below 50% when you apply epoxy. 

 

Step 8: Applying Epoxy Flooring Material 

Now that the floor is prepped, clean, etched, you can apply epoxy. Tape off all the boundaries. Tape off the border or anything you don’t want the epoxy on. Stage your mixing area properly. Epoxy comes in two parts. Part A and Part B. 

• Add about 5% of Acetone to Part A. (To make the epoxy runny and increase pot life).
• Put it on the concrete and use a ⅛” notched squeegee to roll the epoxy evenly on the floor.
• Backroll the epoxy again with a ½ inch nap shed solvent resistant roller. (Get high-quality rollers) 
• Give the floor two coats of Part A and Part B of epoxy. (Let it sit overnight) 
• If you notice bubbles on the floor, take the hundred grit sandpaper or sanding screen on your buffing machine and buff the floor properly. 
• Do the second coat (Ensure to use one kit at a time). 
• Add a coat of Polyurethane 100 to protect the top of the epoxy. 
• If there are imperfections here, scuff up the epoxy.  

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