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RESIDENTIAL COATING SYSTEMS |
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| The Process |
Step 1
The most important part of the coating installation process is the surface preparation. This step will ensure the quality and long life of your floor coating.
The surface preparation process removes a thin layer of concrete, along with stains, dirt, and oils.
The first photo shows the shot blasting process with a Blastrac 8” shot blaster equipped with a vacuum assembly that collects virtually all dust particles. |  |
 | The second photo shows the grinding process with an HTC 420 grinder that is also equipped with a vacuum to keep dust at a minimum. This grinder is used to remove existing coatings, help smooth out pitted floors, flatten and smooth out poorly finished and uneven surfaces, and
create a more uniform finish.
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Next, rough edges, corners, and small protrusions are ground smooth with a hand grinder.
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Step 2
Following the grinding/shot blasting, existing cracks are filled with an epoxy crack filler. Some cracks may be “V” notched to open up the crack and allow the epoxy to bond deeply into the crack and not just on the surface. This ensures a strong repair of the cracks. The control joints are then filled with a flexible epoxy. |  |
| This step promotes a smooth, seamless floor that is easier to clean. |
 | Step 3
Next, if the concrete conditions or the selected coating system requires it, a deep, penetrating epoxy primer is rolled on. The primer will seal and mechanically bond to the concrete. |
| Note: The first 3 steps are usually completed in one day. |
Step 4
After the primer is applied, the flooring system you have selected is installed. |
| Click here to see detailed installation information for specific flooring systems. |
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| Surface Preparation |
An essential factor governing the performance of any protective coating system is the condition and preparation of the concrete surface. Before applying protective coating systems, it is necessary to ensure that the concrete is clean and mechanically sound. The need for adequate surface preparation cannot be overemphasized. Insufficient attention to this step in the process may cause the coating system to fail.
Contaminates must be removed from the floor surface to allow proper adhesion of the new floor coatings. Some contaminates, such as oil and grease, can be washed away with a degreaser. Other contaminates, such as concrete curing compounds or sealers, must be removed mechanically with a shot blaster and/or grinder to ensure adequate removal. Concrete curing compounds or sealers are often applied when the concrete is poured to help with the curing process. After the concrete is poured and cured, it is difficult to determine visually whether a curing compound or sealer was used; and in many cases the owner has no idea who installed the concrete or how it was installed.
Curing compounds and sealers must be removed to allow the new floor coatings to bond properly to the concrete surface. If the compound and sealer contaminates are not removed this could result in the floor coatings peeling off only months after they are installed. Needless to say, the coatings would have to be reapplied, leading to loss of use, inconvenience and much disappointment for the customer. Some floor coating companies prefer to use acid etching to prepare the concrete surface. Acid etching is a wet, messy process, and will not remove the curing compounds and sealers. If the acid comes in contact with any metal surfaces or seeps into cracks down to the rebar embedded in the concrete, it could cause them to rust and deteriorate. Further, the acid etching materials are considered a health hazard.
That is why Ervin Specialty Coatings prepares old and new concrete floors by grinding and/or shot blasting, which is the most reliable method for preparing concrete surfaces for floor coatings. The grinding/shot blasting process removes a thin layer of concrete, along with stains, dirt, and oils, and allows for superior bonding of the coating materials, which cannot be achieved with harmful chemicals and water based cleaners. In addition to the reasons already specified, this method of surface preparation is a superior method, because it helps smooth out pitted floors, flattens and smoothes out poorly finished and uneven surfaces, and creates a more uniform finish.
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