Epoxy flooring is a popular choice for many commercial settings due to its durability, low maintenance, and aesthetic appeal. It provides a seamless, high-performance surface that can withstand heavy traffic, chemical spills, and daily wear and tear. However, the key to ensuring that your epoxy flooring lasts and looks its best is a proper installation process. In this article, we’ll walk you through the steps involved in the installation of commercial epoxy flooring and what you can expect.
Before diving into the installation process, it’s important to understand why epoxy flooring is such a great choice for commercial environments. Some of the benefits of epoxy flooring include:
The first step in any commercial epoxy flooring installation is an initial consultation. During this consultation, you’ll discuss your specific needs, such as the size of the space, the type of traffic the floor will endure, and any aesthetic preferences you may have.
After this, we will conduct a site inspection. This inspection helps identify the condition of the existing concrete slab, whether it’s a new surface or an old one that needs repair. Any cracks, uneven areas, or moisture issues will be noted during this inspection. If the concrete surface is damaged, it must be repaired before the epoxy application can begin.
Surface preparation is arguably the most important step in the epoxy flooring installation process. A properly prepared surface ensures the epoxy will adhere correctly and last for years to come.
The concrete surface must be thoroughly cleaned to remove all dust, dirt, oil, and any other contaminants. This ensures that nothing interferes with the adhesion of the epoxy. Cleaning typically involves sweeping, vacuuming, and sometimes power washing.
Once the surface is clean, it’s essential to create a texture that will allow the epoxy to bond well. This process is called mechanical abrasion and usually involves grinding or shot blasting. Grinding smooths the surface and opens up the pores of the concrete, allowing the epoxy to penetrate and adhere better.
Before applying the epoxy, any cracks, holes, or uneven areas in the concrete must be repaired. This typically involves filling cracks with a specialized epoxy filler or patching compound to create a smooth, even surface. If this step is skipped or done improperly, it could lead to weak spots in the epoxy coating, reducing its durability and lifespan.
Moisture is one of the biggest threats to epoxy flooring. If the concrete is retaining moisture, it can cause the epoxy to bubble, peel, or fail prematurely. A moisture test is conducted to measure the level of moisture in the concrete slab. If moisture levels are too high, a moisture barrier or vapor barrier system will need to be applied before the epoxy installation can proceed.
Once the surface is properly prepared, the next step is to apply a primer. Primers are used to enhance the adhesion between the concrete and the epoxy topcoat. They also help seal the concrete, preventing air bubbles from rising to the surface of the epoxy.
The primer is typically rolled onto the floor and allowed to soak into the concrete. It is important to let the primer fully cure, which usually takes a few hours, depending on the product and environmental conditions. The curing process allows the primer to penetrate the concrete deeply, creating a solid foundation for the epoxy coating.
After the primer has cured, the epoxy coating is applied. Epoxy typically comes in two parts—a resin and a hardener—that are mixed together just before application. The mixture creates a chemical reaction that causes the epoxy to harden and form a durable, seamless surface.
The first layer of epoxy is applied using rollers or squeegees, depending on the size of the area. This base coat should be spread evenly across the entire surface. It’s important to work quickly during this step because epoxy begins to harden within a short period after mixing. The base coat is usually applied at a specific thickness, depending on the application and the desired durability.
If you’re opting for a decorative finish, colored flakes or chips can be broadcast onto the wet base coat to create a unique look. These flakes not only add aesthetic appeal but also increase the floor’s slip resistance. After applying the flakes, excess material is scraped or vacuumed off before applying the topcoat.
Once the base coat has cured (typically after 12-24 hours), a topcoat is applied to seal and protect the epoxy surface. The topcoat provides additional durability and chemical resistance, ensuring that the floor will stand up to the demands of a commercial environment. It also enhances the floor’s gloss and aesthetic appeal, creating a smooth, shiny surface.
The topcoat is applied in much the same way as the base coat—using rollers or squeegees to evenly spread the product across the floor. In some cases, multiple topcoats may be required for extra protection or for achieving a specific finish.
After the topcoat is applied, the epoxy flooring needs time to cure properly. The curing process can take anywhere from 24 to 72 hours, depending on the type of epoxy, the thickness of the application, and the environmental conditions (such as temperature and humidity).
During this time, it’s important to avoid walking on the surface or placing any heavy equipment on it to ensure a flawless finish. Once the curing process is complete, the floor will be fully hardened and ready for use.
After curing, the contractor will perform a final inspection to ensure that the epoxy coating has been applied correctly, that there are no imperfections or weak spots, and that the floor meets the client’s expectations.
After the installation is complete, maintaining your new epoxy floor is crucial for ensuring its longevity. Fortunately, epoxy floors are relatively easy to maintain. Regular sweeping, dust mopping, and occasional wet mopping with a neutral cleaner are typically all that’s required to keep the surface looking pristine.
For high-traffic areas, it’s important to schedule periodic inspections and touch-ups to address any potential wear spots or damage that may occur over time.
The installation process for commercial epoxy flooring is thorough and precise, but it’s essential for achieving the durability and appearance that make epoxy floors such a popular choice. From surface preparation to the final topcoat, each step is crucial for ensuring that your epoxy floor performs well in even the most demanding commercial environments.
If you’re considering epoxy flooring for your commercial space, working with a professional contractor who understands the importance of each step is key. A properly installed epoxy floor will not only look fantastic but also provide years of reliable service. Contact Stout Repairs today to learn more about how we can help you with your commercial epoxy flooring needs!
320 S Billings Blvd Unit A, Billings, MT 59101
Montana, Wyoming, North Dakota, South Dakota, Colorado, Utah and Idaho
