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Our Step-by-Step Epoxy Flooring Installation Process
At Epoxy Floors NJ, we believe a floor is only as good as the preparation behind it. Since 1988, our team has refined a rigorous installation process designed to transform vulnerable concrete into a high-performance, seamless surface. Whether we are working on a heavy-duty warehouse or a custom showroom, we follow these critical steps to ensure a lifetime of durability.
1. Mechanical Surface Preparation
The most common cause of epoxy failure is poor preparation. We begin by using industrial-grade diamond grinders to “profile” the concrete. Unlike acid etching used in DIY kits, mechanical grinding opens the pores of the slab, allowing the epoxy to “bite” into the surface for a permanent mechanical bond.
Why Our Installation of Epoxy Flooring Is Second To None
2. Crack and Joint Repair
We never coat over a compromised foundation. Our team meticulously inspects the slab for cracks, pits, or spalls. We use high-strength epoxy fillers to repair these imperfections, ensuring the final finish is perfectly level and structurally sound.
3. Moisture-Mitigating Primer
New Jersey’s climate can lead to moisture issues in concrete. We apply a specialized moisture-vapor barrier primer that seals the slab. This prevents “outgassing”—the formation of bubbles caused by air escaping the concrete—and protects the floor from hydrostatic pressure that could otherwise cause delamination.
4. High-Solids Base Coat
Once the primer is set, we apply a 100% solids industrial epoxy base coat. This “body coat” provides the necessary thickness and impact resistance to withstand heavy machinery, vehicle traffic, and daily wear and tear.
Installation of Epoxy Flooring since 1988
5. The Decorative Layer
Depending on your chosen system, this is where the transformation happens:
Flake Systems: We broadcast decorative vinyl chips into the wet base coat until the floor is fully saturated.
Metallic Systems: We hand-swirl specialized metallic pigments into the resin to create a unique, marble-like aesthetic.
6. High-Performance Topcoat
After the floor is cured and excess flakes are removed, we apply the final “armor.” We use a polyaspartic or urethane topcoat that provides extreme scratch resistance, chemical protection, and UV stability to ensure your floor never yellows over time.
The result is a beautiful, easy-to-clean floor that is built to last for decades. Contact us today for a free consultation and let our experience work for you.
FAQs
A typical professional installation takes between 2 to 3 days.
Day 1: Mechanical surface preparation (diamond grinding) and crack repairs.
Day 2: Application of the primer and base coat (plus decorative flakes or metallic pigments).
Day 3: Scouring/cleaning and application of the high-performance topcoat. Larger commercial or industrial projects may require additional time depending on the square footage and the specific system being installed.
While drying times vary based on humidity and temperature, the general timeline is:
Foot Traffic: 12 to 24 hours after the final topcoat is applied.
Heavy Items/Furniture: 48 to 72 hours.
Vehicle Traffic: 2 to 3 days to allow the epoxy to reach full chemical cure and maximum hardness.
At Epoxy Floors NJ, we strictly use industrial diamond grinding. Acid etching (common in DIY kits) often fails to open the pores of the concrete deeply enough and can leave moisture or chemical residue behind. Diamond grinding creates a specific “profile” (texture) that allows the epoxy to form a permanent mechanical bond with the concrete, preventing peeling and delamination.
Yes. Our installation process includes a dedicated repair phase. we use high-strength epoxy injectors and mortars to fill cracks, spalls, and pitted areas. By repairing these imperfections before the base coat is applied, we ensure a seamless, level finish that is often stronger than the original concrete slab.
We prioritize safety by using high-solids, low-VOC (Volatile Organic Compounds) materials. While there may be a slight “new floor” scent during the application, our coatings are designed to be safe for residential, commercial, and even food-grade environments. If you have specific sensitivity concerns, we can provide data sheets for the specific resins we plan to use for your project.
Transform Your Space with Professional Epoxy Flooring
High-performance epoxy floor systems engineered for industrial and commercial environments in New Jersey.