A Contractor's Guide to Surface Renewal: Applying Epoxy over Old Concrete
Epoxy coatings are an excellent solution for rejuvenating old, worn concrete surfaces. But before applying a new system, it's crucial to follow a precise process to ensure a durable, long-lasting finish. At Empire Coating Solutions, we'll walk you through the essential steps for preparing and applying epoxy on older concrete, while highlighting common challenges and solutions.
1. Assessing the Concrete's Condition
Before any epoxy work begins, a thorough assessment of the concrete is crucial. Older surfaces often suffer from cracks, pits, and unevenness. All structural damage must be repaired to create a stable base for the epoxy.
Another critical factor is moisture. Older concrete may absorb water over time, which can interfere with the epoxy's adhesion. Moisture testing is essential to ensure the surface is dry enough. If moisture levels are too high, it could lead to bubbles, delamination, or peeling after installation. Consider using a moisture vapor barrier if you are dealing with a damp slab.
2. The Foundation: Proper Surface Preparation
The key to any successful epoxy installation is surface preparation. Without it, even the best epoxy products will fail.
Clean: The first step is to remove all dirt, oil, and grease that could hinder adhesion. Industrial-grade cleaners and degreasers are typically used for this purpose.
Profile: Next, concrete grinding or shot blasting is used to roughen the surface and create the ideal profile for epoxy adhesion. Contractors should aim for a Concrete Surface Profile (CSP) of 2 to 3 for most epoxy coatings. A rougher texture helps the epoxy bond securely, ensuring a longer-lasting finish. We recommend against acid etching for this process, as mechanical methods are safer and more effective.
Repair: If the old concrete has deep cracks or pits, these must be repaired using high-quality patching compounds. The repairs need to be fully cured and sanded to create a level, seamless surface before coating.
3. Applying the Epoxy Coating
With the surface properly prepared, it's time to apply the epoxy.
Prime: Begin by applying a primer. A primer enhances adhesion and helps prevent air bubbles from forming during the topcoat application.
Apply Main Coat: Follow the primer with the main epoxy coat, ensuring an even application across the floor. Depending on the wear and tear of the old surface, additional coats may be necessary to achieve the desired thickness and durability.
Finish: We recommend applying a final, strong topcoat once your main epoxy base has fully cured. This will help seal in your hard work for years to come.
Conclusion
Applying epoxy over old concrete can restore its durability, appearance, and functionality. By following proper surface preparation steps, addressing any underlying issues, and using the right epoxy products, contractors can ensure a high-quality, long-lasting finish. For the best results, always invest in quality materials and equipment to maximize the effectiveness of your epoxy coating.
At Empire Coating Solutions, we are your one-stop shop for all your concrete and epoxy needs. Our support team is here to provide guidance on products, projects, and everything in between.
