Diy Epoxy Living Room Floor

A self-leveling epoxy floor coating being applied to a concrete floor.

Image credit: T.SALAMATIK/Shutterstock.com

While there are a number of professional floor coating companies that operate both nationally and internationally, installing your own epoxy floor coating can be a cost-saving and fulfilling way of getting the job done. Although a garage or exercise area might not be part of your house you most want to show-off, installing an attractive epoxy floor coating can help make it more appealing and save money on costly repairs to unsightly cracks and blemishes. Epoxy coating can also be used as preventative maintenance for concrete flooring.

This article will explain the basic steps needed to correctly prepare and apply an epoxy floor coating and will list the different materials and tools that will make the job go easier and help to assure that the result turns out well. It is important to always read the manufacturer's instructions that accompany the floor coating product that you have selected. Also, make sure to have adequate personal protection equipment on hand to use during the different steps to prevent injuries.

Process Overview

The process for applying an epoxy floor coating can be divided into the following steps:

Familiarize yourself with the kit contents & plan the project
Remove all items from the area to be finished
Assemble the necessary tools and supplies required
Clean the floor
Prepare the floor surface
Apply the base coat
Add the decorative chips or flakes
Apply the top coat or finisher coat

Kit Contents

The specific instructions that come with the epoxy floor kit should be reviewed and the contents of the kit examined so that you become familiar with the recommendations that apply for the product that you will be applying. This includes such details as the recommended application temperatures, approximate cure times, how long to wait before applying the finishing coat, and the amount of coverage to be expected for a given volume of epoxy coating. The kit will usually come with the coating in two separate containers – a part A that is usually tinted to the desired floor color and a part B that contains the hardener. Other items that may be included will be a measuring stick to get the proper mix of part A and B for the coverage area, a mixing paddle for use with a drill, protective gloves, decorative chips or flakes that are designed to give the floor an attractive appearance and help reduce its slipperiness, a paint roller, a paint brush, and a finish coat or top coat such as a clear coat. Some kits may also supply a set of shoe attachments that contain a set of spikes protruding out of the bottom of the attachment. The purpose of these shoe attachments it to reduce the surface area over which your weight is distributed when walking on the floor surface while the application process is occurring. These attachments will allow you to stand and walk on treated areas of the floor before the coating is fully cured without disturbing the coating.

Before beginning, double-check the square footage of the area to be coated and make sure that you have a sufficient quantity of the product on hand to cover the area. Most manufacturers suggest allowing for 15% of the product to be lost due to adherence in containers, rollers, etc. Having just enough probably means that you have too little, which can result in the product being applied too thinly with a noticeably pooer result.

Area & Project Preparation

The first step in the process is to prepare the area that will be coated by removing all items from the floor so that the entire surface can be accessed and no coating will be accidentally spilled or splashed where it is not wanted. Ideally, the project should be planned with an eye on the expected weather conditions and to take place over a span a course of several days when the temperatures are moderate and rain and high humidity are not expected. Becoming familiar with the specific steps and cure times for your specific product will help with planning a reasonable schedule for the project.

Tools and Materials

In addition to the contents of the epoxy flooring kit, the necessary tools, supplies, and personal protective equipment (PPE) should be assembled and available. A suggested list of items that might be needed is found below. Depending on the kit purchased, some of the supplies may be included in the kit.

PPE & clothing
- Disposable protective gloves such as nitrile or latex variety
- Safety Goggles
- Rubber Boots
- Long sleeve pants and shirt
- Protective masks or respirators
Supplies & Tools
- 5-gallon or larger mixing pail
- Paddle mixer for drill
- Cordless or corded drill
- Paint Rollers and Paint Brushes
- Paint roller handle
- Paint stir sticks
- Acetone or MEK for cleanup
- A rubber or foam squeegee
- Plenty of rags or toweling
- Drop cloths or tarps
- Low adhesion painter's tape
- Broom
- Stiff bristle brush with handle
- Hose
- Pump style garden sprayer
- Air compressor with an air gun or leaf blower
- A pressure washer if available

Having multiple rollers and brushes is useful, especially for projects that cover a larger area as the roller and brush will get stiff and difficult to work with as the epoxy coating that adheres to the roller or brush begins to cure.

Cleaning the Floor

The first step in how to apply epoxy flooring is cleaning the floor. Once furniture and other items have been cleared from the area, any stains should be cleaned as best they can. Start by sweeping the floor or using compressed air or a leaf blower to remove any loose direct and debris from the floor. Concrete cleaning products are available at the big box home improvement stores or your local hardware store to address tougher stains such as oil stains, grease, and other conditions. Apply the product as directed and then work it in using a stiff nylon bristle brush. More difficult stains may require several treatments. A pressure washer can also help lift some difficult stains from the concrete.

If a stain is too difficult to clean with consumer or industrial products, other options include using a sander, a sandblaster, or a high-powered grinder across the entire floor space. This can smooth out the floor and make it ideal for epoxy coating. The process is especially important if there is an old layer of paint, epoxy resin, or some other sealant still present on the floor. To test for sealant, pour a small amount of water onto the floor. It should soak in. If it doesn't, and instead forms beads of water on top, the floor has already been sealed.

Moisture is another thing to avoid. A method recommended by Ezine is to tape down a 3 x 3 piece of plastic tarpaulin for two days and then check it to see if there is moisture gathered on the underside of the plastic. If moisture is present, consider some other form of coating. Another thing to look for that is indicative of moisture seeping up through the concrete is the presence of effervescence, a white powdery substance that is the result of salts in the concrete being brought to the surface by moisture. These areas must be properly treated to assure good adhesion of the floor coating.

Preparing the Floor Surface

Once the floor has been tested for suitability and properly cleaned, the surface should be inspected for any defects or areas that require attention prior to the application of the epoxy floor coating This includes repairing chips, cracks, or possible filling up the expansion joints in the concrete with a self-leveling sealer to level out the surfaces. If needed this is where the sander or grinder comes into play. If you do not own or have access to a grinder, putting a board of sandpaper on the end of a long stick or pole and using this tool like a mop can do the job for you. All divots, chips, and incorrectly aligned joints need to be repaired. If there is a break in the concrete, the crack should be filled to make the disjunction level. Any sprouting nails or screws should be driven in or tightened so they are not out of alignment when the primer is applied.

The last preparation step once the floor has been cleaned is to acid etch the concrete. This will increase the surface roughness and assure that the epoxy coating will have a good bond to the concrete. Follow the supplied directions for mixing the acid etch with water. Use a garden sprayer or a plastic bucket to mix the etch and then apply the etch to a wet floor and agitate the surface with a stiff nylon bristle brush. Work in sections and be sure to don all the proper PPE including long sleeve shirt, long pants, rubber boots, safety goggles, face protection, and gloves.

After the acid etch is completed, rinse with a hose and dilute the run-off so that it does not damage plants, lawns, or other surfaces. Allow the surface to thoroughly dry before applying the base coat application. A fan to circulate air will help with the drying process. As it is important for the surface to be completely dry before proceeding, the importance of planning the project around weather conditions now becomes clear.

Each of these preparation steps may be performed multiple times to ensure the whole surface is well prepared for the application of the epoxy floor coating. The key to a quality finished end result is doing a thorough job with preparation, so do not rush these steps. Take the time to do proper preparation and expect that this part of the process may take several days.

Base Coat Application

Once the entire floor surface has been prepped for coating, it is time to apply the base coat. A final step before starting is to remove any dust from the floor surface using an air compressor to obtain as dust free a surface as possible. If you are doing a garage floor, for example, tape off the edge where the concrete floor meets the driveway. Also tape off any areas that are not going to be coated such as walls. Choose a location close to the area being coated to perform the base coat mixing, ideally one that is as flat as possible to allow proper proportions of coating and hardener to be mixed. Follow the specific directions that the manufacturer of the epoxy coating provides for the quantity of product to apply for a given coverage area and desired coating thickness. Use a mixing bucket, paddlewheel mixer, and drill, and mix the proper amount of part B hardener to the part A coating. Unless the area being treated is very small, it usually makes sense to work in sections, so be careful to only mix enough product to cover the area being worked. Once the product has been well mixed, you can begin to apply the coating.

Don the appropriate PPE and use spiked shoes if possible, to minimize contact with the flooring surface. Epoxy coatings are usually applied by dumping the coating directly onto the concrete and then using a squeegee or paint roller to smooth out the coating. The products are usually self-leveling so the primary goal is to get a consistent treatment and remove any air bubbles that might form. Work the coating with the squeegee in right angle directions until the appearance is smooth. Only the should you mix more epoxy and move on to the next area to be worked. As you continue, check the condition of the roller, and change it out if it becomes too stiff to produce a smooth finish.

Adding Decorative Chips

As the base coat begins to cure, check the surface appearance to make sure no fisheyes (bubbles) are forming. Follow the manufacturer's suggested time table for when to apply decorative flakes or chips to the flooring, which should be done before a full cure occurs. Some appliers have suggested tossing the chips upwards towards the ceiling to allow them to disperse more uniformly upon the surface, as opposed to tossing them downwards, which may result in chips clustering over smaller patches.

Continue to apply the flakes or chips as needed to achieve the result desired, applying in sections following the base coat application.

Applying the Top or Finish Coat

After the base coat and decorative flakes have been applied, it is time to apply the second coat: epoxy finisher. The finisher or top coat is applied in the same manner as the base coat, by applying directly to the floor and smoothing with a roller or squeegee. Some product kits may include an anti-slip abrasive, such as aluminum oxide powder, which can be mixed in with the top coat to produce a surface that is less slippery. The anti-slip abrasive is especially important for applications on steps where a fall might more easily occur.

Once the top coat has been allowed to set overnight, the floor should look like a showroom. A quick sweep and a polish and the floor will be attractive, easy to clean, and will make sure to keep your floor damage-free.

Use Acetone or MEK to clean up any tools or spills, and properly dispose of any used rollers, brushes, paint sticks, and other disposable materials.

As far as how to clean epoxy floors, you can just use a dust mop or Swiffer, or vacuum as you would a regular floor, but be sure to clean up any spills promptly. The floor coating should last for years to come and will provide protection as well as improved light reflection, making it easier to spot that dropped fastener. Check the product manufacturer's recommendations for when heavier shelving or other items can be moved back into place. Also, a longer cure time may be needed depending on temperature and humidity. For garage floor applications, follow the manufacturer's advice on when to park motor vehicles on the newly coated floor to avoid hot tire pickup.

Summary

This article provided a look at the process, materials, and tools needed to apply an epoxy floor coating over a concrete floor. For information on other topics, consult our additional guides or visit the Thomas Supplier Discovery Platform where you can locate potential sources of supply for over 70,000 different product and service categories.

Sources

https://www.coppsindustries.com/blog/ultra-clear-epoxy-101-table-top-epoxy-vs-casting-epoxy/

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Diy Epoxy Living Room Floor