Floor Coating Installation Process
Our team has an established process that we use for our floor-coating installations, both residential and commercial applications. This method has been tested and improved over time in order to provide our customers with the most seamless, efficient process available. In most instances, our floor coating installations can be finished in a single day, getting you back to business as usual faster!
CHECK OUT THE STEP BY STEP BREAKDOWN:
The installation process starts with determining the type of concrete you have depending on its Hardness, Moisture Content, and Structural Condition. Each of these variables contributes to how we approach the next and most important step—concrete: preparation.
To give us the best adhesion possible, we utilize either a Blastrac shot blasting equipment or a Lavina diamond grinder to create an extremely course and porous surface and to remove any weak or deteriorated concrete.
In the case of many floors, we have to use special menders and fillers in order to fix any pits, cracks, and/or spalls that are present in the existing concrete floor. After the preparation process, we use a diamond grinder with a V-blade to open up and abrade both sides of the crack, or the shot blaster clean and remove weak concrete. This gives the damaged area a course profile for our repair material to bond to. Next we mix our mender material and overfill the crack. When the material is fully cured (typically seven to ten minutes) we grind the overfilled material flush with the concrete surface. This leaves the floor smooth and level. Finally, the repair process is concluded by vacuuming the floor and using a leaf blower to flush out any remaining debris.
Prior to coating the floor we will start with coating all vertical surfaces: “Curbing” is the vertical surface typically found around the perimeter of the concrete slab. We mix up a small amount of our base coat, a 100% solids self-priming pure polyurea, which we brush on to all vertical surfaces. Next, we use a scraper to pull the pile of chip vertically against the wall, leaving the surface fully covered. We then vacuum to recover any loose chip left behind on the floor. Next, we mix a small amount of our base coat to cut in all the edges around the floor. We then mix one gallon of base coat at a time and spread it out covering approximately 175 sq. ft. This is achieved by pouring the mixed coating onto the floor in a line and using a roller/squeegee, to spread the material in an even manner to the desired thickness. We repeat the mixing and rolling process until the whole surface is covered completely.
When the floor is coated completely, we mix our flake in a big tub to insure an even blend of colors. We then broadcast the flake into the wet coating by hand, covering the whole floor with the flakes. By using mass quantities of flakes, we ensure that the floor is completely covered, leaving it uniform in color and texture. The drying period on our basecoat is typically a 45-60 minute cure time depending on outside temperatures.
Once our basecoat is fully cured we “scrape” down the flake. With metal blade scrapers we walk along the floor surface putting pressure on the blade to “cut” and “scrape” any loose or vertically standing flakes. In most applications we scrape the floor from front to back and also side-to-side to ensure we have hit all angles of the chip. This results in the floor having a nice even texture. At this time we also scrape vertical surfaces by hand to knock down any loose flake. We then vacuum to recover any loose chip left behind on the floor.
After our floor is prepped, coated, flaked, scraped, and vacuumed, we can start our final step — the application of the clear coat. Typically, we use a 96% solids Polyaspartic Polyurea UV stable clear coat that is applied at a rate of 145-160 sq. ft. per gallon. We start by clear coating all of the vertical surfaces and then brushing the perimeter of the floor itself. With the clear coat, instead of mixing one gallon of product at a time, we mix the entirety of the product needed to cover the whole floor. We pour the mixed product directly on to the floor and use a soft squeegee to spread the coating to our desired thickness. Then we use an 18 inch roller to back and cross roll the floor. This takes out any lines left behind by the squeegee and leaves a nice and even clear coat over the entire floor.
At this point we clean up and leave the floor to dry. After six to eight hours you can confidently walk on your new coating and after 24 hours you can park and drive on the coating. We hope you fully enjoy your new floor!