EPOXY FLOORING
Solid, Metallic, Flake, Clear Epoxy
Epoxy flooring has become one of the fastest growing applications in the decorative concrete industry.
We have been involved with this application for over 10 years. These floor systems are often specified for warehouses, airplane hangars, schools, medical facilities, and restaurants. The durability, ease of maintenance, and seamless look are highly desirable. Unfortunately, our industry has been inundated with applicators who do not follow the proper steps during application. These floors are 100% solids and do not tolerate high moisture emissions.
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To combat this, we test every floor to verify the vapor emissions do not exceed what our epoxy can tolerate. When we find unusually high moisture content, we include a moisture mitigation system into our bids. Prepping for an epoxy application is the most important part of the process. We have invested heavily in the correct grinding machines, vacuums, and tooling to assure the floor prep is completed to industry standards. Our grinding is done using our dustless systems in accordance with OSHA guidelines. Once grinded we often encounter hairline cracks that are caused by concrete settling over the years. These cracks cannot be ignored for a truly seamless epoxy application. We treat all cracks with a deep epoxy injection that fills the void. This allows for a smooth seamless application of the epoxy. Depending on the type of epoxy selected we follow a 3-step process. Prime the floor, apply our solid, flakes, or metallic epoxy, and topcoat with a chemical/stain resistant urethane.
EPOXY FLOORING PROS AND CONS
Pros
100% solid epoxy is non-permeable thus allowing for easy maintenance and cleaning.
Extremely durable and creates a lifetime coating. Ideal for all indoor or enclosed settings.
Creates entirely new smooth coating that hides any existing imperfections in the concrete. Perfect for older concrete or damaged concrete slabs.
Seamless look is great for large spaces.
Metallic epoxy creates a one-of-a-kind modeled effect that cannot be duplicated with any other products.
Wide range of color selections.
Leaves a beautiful sheen and reflective shine.
Can have “shark-grip” additive blended into topcoat for slippery settings.
Cons
Cannot be applied in direct sunlight. Epoxy is not 100% UV stable. It is not recommended for patios, pools, or other areas that receive direct sunlight all year.
Higher price point than stained concrete.
POLYMER OVERLAYS
Spray Deck, Tape Patterns, Stamped, Smooth T Roweled
Our overlay systems can be applied in several different ways. These options are a great alternative to staining damaged, old, pitted concrete.
When applying an overlay, we clean the existing surface to assure the new layer of material will permanently bond to the substrate. Depending on the selected application we apply a thin new layer of material that is far stronger than the concrete below. A popular application is “spray-deck” and is often seen surrounding pools and patios. We specialize in not only the traditional “spray-deck” but in taping down custom patterns to leave a unique stone or brick look for our clients.
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Often, we proceed with a thin skim coat to create a fresh template to apply our stain system. This fills any voids and leaves the surface clean and new preventing the unwanted blemishes and imperfections inherent with old concrete. For our clients with a custom design in mind we offer stamped overlay options. These coatings are more expensive but can emulate stone, wood, brick, and other common flooring options. We can discuss your vision and decide what will work best for your project and budget!
POLYMER OVERLAYS PROS AND CONS
Pros
Great way to repair and renovate old, dilapidated concrete.
Creates a new surface for stamping or staining.
Numerous ways to apply. We have options for every budget and vision.
Perfect for exterior applications such as pool decks, patios, porches, sidewalks, and driveways.
Durable coating that can handle impact, tire traffic, and other abuse.
Once sealed with our topcoat product these floors are easy to maintain with a household pressure washer or hose and spray nozzle.
Cons
Labor intensive application.
Cannot be applied while surface temperature is over 90 degrees.
STAINED CONCRETE
Acid Stained Concrete
Acid stained concrete is one of the original decorative concrete applications.
These applications had grown greatly in popularity during the early 2000s and continue to be a popular option today. The primary benefit of acid stain is the chemical reaction it causes when applied to cleaned concrete. Instead of the color sitting on top of the surface acid stain causes a chemical reaction that changes the color of the concrete. While a viable option the industry has advance the other types of stain leaving acid stain in the past.
Acetone and Water-Based Dye
Over the last decade our suppliers have perfected these alternate options to acid staining.
Both the acetone and water-based dyes are similar in application and appearance. Each project is different, and we base our selection on the factors presented during our on-site review. With the innovations in topcoat sealers these staining options have come to the forefront of the decorative concrete industry. While these do not cause a chemical reaction with the concrete, they do penetrate the pores leaving a permanent stained surface. This stain is than locked into place by a commercial grade sealant specifically selected for each job.
STAINED CONCRETE FLOORING PROS AND CONS
Pros (Acid stained concrete)
Creates a permanent chemical reaction with the concrete surface. (This is beneficial in extremely high traffic areas or areas that will be exposed to repeated impact or scratching.)
Leaves a unique modeled effect creating beautiful variegation in selected colors.
Has a track record of success and is a staple in the decorative concrete industry.
Economical option.
Wide range of colors to choose from.
Pros (Acetone and water-based dye)
Creates permanent long lasting stained effect.
New-age sealers create a barrier of protection from impact and scratching.
Easier to customize and blend color selections.
Covers most imperfections that would be apparent with an acid stain application.
Much cleaner process that can be done indoor, outdoor, and on all ages of concrete.
Economical option.
Wide range of color selections.
Cons (Acid stained concrete)
Due to the chemical reaction, we often have imperfections from previous construction or wear and tear on the concrete surface being stained. If you are planning on choosing acid stain expect there to be imperfections and blemishes in the finished product.
Acid stain application can be messy due to the residue and water needed in cleaning. This option is better suited for outdoor or new construction.
Not recommended for older concrete surfaces that have been exposed to years of wear and tear.
Cons (Acetone and water-based dye)
GRIND & SEAL
Over the last 5 years we have procured multiple machines that aid in our preparation and applications.
Recently we have found that many clients need an economical solution to failing decorative concrete, dilapidated slabs, and poorly finished concrete. Our dustless grinding system has offered an ideal solution on numerous occasions. We use a special machine that not only grinds off the damaged concrete and failed coatings but leaves behind a surface that can than be stained and sealed. This often saves our clients 50% vs an overlay or tear out. We also assist other applicators in grinding and preparing their floors for them. If you need help with damaged decorative coatings, concrete, or a rough finish please give me a call.
GRINDING GRIND + STAIN PROS AND CONS
Pros
Economical solution to failed applications.
Creates a clean surface for our stain system to be applied on.