Epoxy Coatings on Concrete: Tough to Beat

Epoxy coatings produce an attractive, durable surface when placed over concrete floors. When properly mixed and applied, epoxy coatings produce a seamless and hard, chemical and solvent-resistant finish that’s tough to beat. Epoxy coatings are suitable for commercial and industrial applications. We have used Prime Coat Coating Systems’ products and installation services. Tnemec Company, Inc. is another manufacturer of high-performance architectural and industrial coatings.

 Applying the epoxy to the concrete slab base layer is a pretty straightforward process. But what happens when the concrete slab is unsuitable for the epoxy coating?

 Like all construction, the base layer of an assembly must be solid and sturdy. Concrete floors may appear to be suitable for epoxy coatings. But watch out when the surface is ground down to accept the epoxy coating! Unstable concrete may be exposed and the base will not be suitable to receive the epoxy coating.

 What can we do when the flooring prep exposes unstable concrete that must be replaced?

1. Identify the weakened, broken slab areas and remove them.
2. Pour new concrete to make an unbroken slab area.
3. Wait until the new concrete cures.
4. Install the epoxy coating on the concrete slab.

Seems simple enough, right?

But #3 is a big headache! Concrete takes 28 days to cure before the epoxy coating can be installed. That is a significant project delay!

And typically, the flooring is done toward the end of the construction project. Everyone is in a big rush to get the project done, so the delayed flooring is a big problem.

So what can be done to accelerate the project schedule?

Concrete accelerator is the key to getting the project back on track. Although it is expensive and difficult to implement, the time saved by using accelerator is very valuable. Let’s take a look at how we make it work:

1. Order special “dry” concrete from the batch plant.
2. Add water to the concrete in the truck when it arrives on the construction site.
3. Add a special admixture to the concrete in the truck. This admixture allows the concrete to set up quickly-within 24 hours!
4. Place the concrete quickly!
5. Cover the new slab areas with plastic to prevent shrinkage while it is drying.
6. Remove the plastic after 4-12 hours so that it doesn’t stick to the slab.
7. Be sure to wash out the concrete truck immediately and dump the washout at the site.     

Problem solved! Now that the concrete is solid and cured, the project is back on track and the finish coating of epoxy can be placed over the concrete.