Step 1. Prepare The Concrete For The Epoxy Flake Floor System

All surfaces must be properly prepared. We thoroughly clean and free any contaminants that may inhibit the adhesion of the epoxy. The slab should be profiled to a minimum CSP-2 from grinding or shot blasting. You want the surface to be similar to 60 or 80 grit sandpaper. This gives the resin something to grab onto. It is imperative that all dust is thoroughly vacuumed after prep. All larger cracks and defects will be filled and profiled to match the main surface.

Step 2. Apply Poly 90 and Pigment

We apply a primer/base coat of Poly 90 epoxy. Poly 90 is in the same family of products as truck bed liner! If the prepared floor is extremely porous or shows much surface defect, a pure primer coat will be added before the initial broadcast coat. This will ensure maximum adhesion to the prepared substrate. Both A and B parts of the resins material are mixed separate to ensure separation has occurred. For application, we mix 2 parts A with 1 part B by volume with a low speed mixer for three minutes. Once we mix it, we immediately begin pouring the material onto the floor in long usable ribbons.

Step 3. Broadcast The Flakes

Once we back-rolled the material we begin broadcasting the flakes. The way we do this is to place several pounds of the flakes into a clean bucket and take small handfuls of the chips and toss them in the air onto the tacky floor. It is important to throw them upward to get a good spread and faster coverage. If you choose to do a "partial broadcast", our goal is to get a good even spread onto the floor. If you choose "full broadcast", we follow the same procedure but we use larger handfuls of chips.

Step 4. Scrape the Floor

The floor will be ready for the protective topcoat once we remove any chips that are protruding irregularly. We do this with a floor scraper or a large drywall knife threaded onto the end of a pole. We slide the blade over the entire floor knocking down the chips that are sticking into the air. Once complete we scoop up the loose chips and then vacuum the floor thoroughly to remove the remaining pieces.

Step 5. Apply A Protective Topcoat

Lastly, we apply a protective topcoat of Polyaspartic 85. A single topcoat is used as it will allow more of the chip texture to be present. This can be reduce by applying a second topcoat by mixing up the proper amount of material and ribbon out on the floor. Using a flat blade squeegee we drag the material back and forth, spreading it out. Using a 3/8 nap roller, we back roll the material until even and free from any marks.