Pec Floors

How to install Epoxy Flake

How To Install Epoxy Flake System In Your Garage Step by Step

Epoxy floor coatings are attractive, economical, and durable flooring solutions for residential and commercial applications. Installing epoxy floor coatings can be difficult, but it’s a low-maintenance and durable option for flooring in the long run. Let’s explore how we install one of the most popular and durable epoxy systems, the Flake System (Vinyl Chip System).

1st Step: Diamond Grinding & Repair Concrete

Preparation is the most important part of the process, ensuring that the underlying concrete and epoxy form the chemical and structural bonds needed for a long-lasting floor coating.

Diamond Grind Dust Free

First, the floor is diamond-ground to clean and profile the surface. Our grinders are connected to a dust collection device, so the process is dust-free. Surface profiling allows the epoxy to penetrate into the concrete slab. We begin with 30grit diamond blades to smooth the surface and expose cracks, holes and other imperfections in the concrete. Please note that in some cases a more aggressive grit needs to be used such as 16grit or even PCD Scrapers to remove an old coating or other flooring adhesives.

Patch Holes and Cracks

Before patching begins it is crucial that the substrate is clean, by using a powerful vacuum we ensure that holes and cracks are dirt and dust free for maximal bond of the patching material. We then fill all cracks, holes, and imperfections in concrete with epoxy patching materials or fast cure cement. Every patching material we use has a specific function and are used to treat different types of holes or cracks.

Detail and Angle Grinder

An angle grinder with a diamond cup wheel can be used to level, smooth and polish concrete. We Also use it to treat the floor adages (where the wall meets the floor) or any other areas where our industrial grinding machine can’t reach. The use of angle/hand grinder is extremely important to ensure continues floor profile and therefor avoid weak bonding spots. We then move up to 70grit diamond blades to create the optimal substrate profile for epoxy bonding.

2nd Step: Apply Epoxy Primer/Basecoat

The Flake epoxy system is a 3-(4)-layer structure made by a (primer), basecoat, flakes/chips broadcast and a topcoat. The use of epoxy primer depends on the type of concrete, a soft/porous concrete will require the use of epoxy primer.

Remember: Epoxy is large family name to multiple types of chemicals that breaks down in. different ways with respect to properties and performance. Different substrate conditions such as: moisture, UV exposure and temperature will determine a specific type of epoxy designed to function under such conditions. At PEC FLOORS we ensure to match your floor condition to the right Epoxy in order to achieve the best result possible.  

Surface Cleaning

Before any type of epoxy application, it is crucial that substrate is completely dust free in order to enhance bonding. Perfect vacuum is not enough! The use of microfiber along with denatured alcohol or acetone (not water) is essential to remove dust trails that otherwise will weaken bonding.

Epoxy Basecoat Application

The epoxy basecoat penetrates the concrete and provides a foundation to the intermediate broadcast coat. At this time a pigment is added (according to the flakes chosen) to our industrial-grade, low viscosity epoxy, used for maximum penetration and bonding with the concrete slab. The epoxy is poured on the floor and being spread evenly using a special trowel. Then the use of an adage roller and a roller is important to provide an even and seamless coating.

3rd Step: Broadcast the Chip/Flakes

Flakes are used to achieving various styles and appearances to the floor. It may be either full flake or partial flake broadcast. These flakes come in different colors, shapes, appearances, blends, and sizes.

Broadcast Flakes.

Once the epoxy basecoat is applied and is still in liquid form (wet), the decorative flakes are broadcast on the floor.

Scrape Excess.

Once the epoxy is dry (various drying times depending on the epoxy used) scrape any excess and partially bonded flakes to achieve a uniform surface.

Reclaim Excess Flakes

using a high-power vacuum/dust collector to ensure no loose flakes are present on the floor before the final step.

4th Step: Apply Topcoat

Epoxy floors are resilient, impact resistant, somewhat flexible and hard. They definitely supplement an efficient, durable and long-lasting floor coating system by providing build thickness. However, in most cases the best results come from an epoxy flooring with a thin film of Polyurethane or Polyaspartic topcoat. These will add chemical resistance, scratch resistance, UV resistance (yellowing), gloss retention and easier cleanability.

Polyaspartic Topcoat

Once the epoxy has dried, flakes are scraped, and the surface is clean it’s time to complete the job with a polyaspartic clear topcoat. Using a roller for this application to spread the material methodically and evenly on the surface.

Back Roll

Back rolling is the technique of going back after an epoxy floor coating has been applied and using a roller to make the final finish of the surface to look uniform.

5th Step: Enjoy Your New Garage!

24-hour dry time is required before your vehicle can be parked on the garage floor. However, we recommend 48-hours to ensure optimal curing. congrats on your new floor!

Important Note:

Safety is the number one priority! wear eye protection, gloves and respirator when prepping a floor and always remember to apply any chemical according to the manufacture recommendation (way of application, mixing/bucket time etc.)