The Definitive Guide to Successfully Installing Epoxy.com™ 100% Solids Epoxy Coatings

1. Confirm the Surface Is Ready

Do not begin coating until the substrate is clean, sound, dry, and properly prepared.

Remove dust, debris, oil, grease, curing compounds, sealers, loose concrete, and anything else that could interfere with adhesion.

Repairs should be completed before coating begins.

The surface profile should be appropriate for the system being installed.

Vacuum the surface carefully after preparation. Dust left behind can become a bond breaker between the concrete and the coating.

Before opening the first container, walk the entire installation one final time.

Look for:

• Dust or debris
• Unrepaired cracks or defects
• Contamination
• Damp areas
• Condensation
• Unexpected surface conditions
• Areas that may be difficult to reach once installation begins

This is your last inexpensive opportunity to correct a problem before epoxy is mixed.

If you discover something on the job that is not covered by the Product Data Sheet, these guides, or your installation instructions, stop and ask before proceeding.

Every installation is a little different.

Recognizing something unusual before coating begins is one of the characteristics of an experienced installer.

2. Confirm Environmental Conditions

Measure and record the substrate temperature, material temperature, and air temperature.

Remember that the substrate temperature usually has the greatest effect on cure, followed by the material temperature.

Also evaluate humidity, dew point, and the possibility of condensation.

A floor can appear perfectly dry and still develop condensation if its temperature approaches the dew point.

Do not begin installation until the environmental conditions are suitable for the specific product being installed.

When in doubt, ask.

3. Plan the Installation

Decide where the installation will begin and where it will end.

Plan the direction of application.

Plan the exit route.

Identify doorways, drains, columns, walls, equipment pads, and other areas that will require cutting in.

Determine where each mixed batch will be placed and how far it must cover.

On larger installations, divide the floor into manageable sections based on the expected coverage rate.

Do not mix until everyone involved understands the plan.

4. Assign Responsibilities

On a small installation, one person may perform every task.

On larger installations, it is often better to assign specific responsibilities.

One person mixes.

One person carries or transfers material.

One person cuts in.

One or more people roll.

On smaller jobs, one person may have responsibility for several areas. Regardless of crew size, every responsibility should be defined before the first batch is mixed.

This is especially important for the person mixing the epoxy.

And once again:

Do not talk to the mixer.

The person mixing the epoxy, not the drill mixer.

Mixing requires concentration. Even a brief interruption can cause the mixer to lose track of time or miss a critical step.

It is better to apologize afterward for appearing rude than to apologize later for an improperly mixed batch of epoxy.

Questions can wait.

The batch cannot.

5. Premix Part A and Part B

Premix Part A thoroughly before measuring or combining components.

Pigments, fillers, and other materials may settle during storage and shipping.

Premix Part B separately as well.

Use separate stir sticks or mixing paddles for each component.

Do not cross-contaminate the containers.

A small amount of Part B introduced into Part A, or Part A introduced into Part B, can damage the remaining material and shorten its usable storage life.

6. Measure the Components

Follow the exact mixing ratio shown on the product label and Product Data Sheet.

Use clean, clearly marked measuring containers.

Use one measuring container for Part A and a separate measuring container for Part B.

Do not estimate.

Do not assume that bucket markings are accurate enough unless they have been verified for the measurement being made.

Take the time to measure carefully.

Epoxy cannot correct an inaccurate mix ratio after the components are combined.

7. Combine the Components

Always add Part B hardener into Part A resin unless the product-specific instructions state otherwise.

Scrape the measured material from the Part B container into Part A.

Maintain the correct ratio by transferring the complete measured quantity.

Do not leave a meaningful amount of either component behind in its measuring container.

Once Part A and Part B have been combined, mixing should begin immediately.

8. Mix the Epoxy

Use a low-speed drill and a properly sized mixing paddle.

Use a mixing paddle appropriately sized for the material, the batch size, and the mixing vessel. With epoxy, the correct paddle is typically larger than most people expect.

Mix for at least three minutes unless the product instructions require otherwise.

Move the paddle through the entire batch.

Scrape the sides.

Scrape the bottom.

Pay particular attention to the lower corners of the pail, where unmixed material can remain.

Avoid whipping unnecessary air into the epoxy.

If you are uncertain whether the batch was mixed correctly, do not use it.

Set it aside and mix another batch.

Removing one questionable batch is far less expensive than removing an uncured section of floor.

9. Add Anti-Skid Aggregate (When Required)

For most floor applications, anti-skid aggregate is strongly recommended.

Measure anti-skid aggregate by volume, not by weight.

A typical loading is 8–16 fluid ounces by volume per mixed gallon unless otherwise specified.

For many installations, approximately 12 fluid ounces by volume per gallon in both coats produces an attractive texture that resembles a fine broadcast floor while remaining practical to clean.

Add the anti-skid aggregate only after Parts A and B have been completely mixed.

Continue mixing long enough to distribute the aggregate uniformly throughout the batch.

10. Apply the Coating

Do not leave mixed epoxy sitting in a deep mixing pail any longer than necessary.

The larger the mass, the more heat it retains.

As the temperature of the epoxy rises, the available working time becomes shorter.

Transfer the material into a roller pan or another suitable shallow container as soon as practical.

When anti-skid aggregate has been added, a roller pan provides much better control than pouring the material directly onto the floor.

If a batch is larger than expected, divide it among two or more roller pans or shallow containers.

Reducing the mass helps dissipate heat and increases usable working time.

Experienced installers usually mix only what they can comfortably install within approximately the first half of the published pot life.

That safety margin becomes even more important as temperatures increase.

11. Maintain a Wet Edge

Plan the installation so each new section joins material that is still wet and workable.

Avoid stopping in the middle of an open floor whenever possible.

Work toward natural stopping points such as doorways, control joints, expansion joints, drains, columns, or changes in elevation.

A lost wet edge can leave visible lap lines or differences in texture.

12. Recoat Procedures

Apply additional coats within the recoat window shown on the Product Data Sheet.

Remember that temperature affects cure.

Warmer temperatures shorten the recoat window.

Lower temperatures extend it.

If the recoat window is exceeded, mechanical abrasion is normally required before additional coats can be applied.

When sanding is required, remove all sanding dust before recoating.

When in doubt, ask before proceeding.

13. Protect the Installation During Cure

The installation is not complete when the roller is set down.

Protect the floor from foot traffic, equipment, water, dust, construction debris, and other trades until the coating has cured sufficiently for the intended service.

Signs help.

Physical barriers help more.

Protecting the coating during cure is part of the installation.

Final Thoughts

A successful epoxy installation is rarely the result of one great decision.

It is usually the result of dozens of small decisions made correctly.

Prepare thoroughly.

Measure accurately.

Mix completely.

Work within the material's limits.

Protect the installation.

Learn continuously.

Ask questions.

Above all—

Especially
when in doubt, ask questions.

One final thought.

Over the years I've found that the installers who ask thoughtful questions before they begin have few to no questions after the floor has cured.

Questions asked before the installation are inexpensive.

Repairs after the installation seldom are.

Continue Learning

This guide is intended to complement, not replace, the Product Data Sheet, product label, Safety Data Sheet, and product-specific installation instructions.

We also recommend reviewing our general installation guidance at:

Epoxy.com Installation Guide – General Installation Do's, Don'ts and Best Practices

Every installation teaches something.

The best installers never stop learning.

Neither do we.

Return to Part 1

Successful installations begin long before the first batch is mixed.

If you would like to review planning, preparation, and the practices that prevent most installation problems before they occur, return to Part 1.

← Return to Part 1 – Planning, Preparation & Best Practices