In our industry, another topic that comes up, more often in the residential sector, is one day floor coating versus two day or three day floors, however you choose to install it. The one day floor coating installations are not a “magic bullet” as a lot of companies try to sell them. It’s not a 1 size fits all solution. While the floor can be installed in one day, you’re able to return the customer back to their floor quicker and there’s less downtime, it’s not always the best solution.

As a professional installer of epoxy floor coatings for over a decade we’ve experienced many different situations that required different types of coatings. When we initially speak with our customers, we ask numerous questions and consider a number of factors that will determine what coatings we need to use. Factors such as the condition of the concrete, moisture presence, chemical exposure, types of traffic, and environmental temperatures help us to consider the correct coating system.
For many one day floor coating installs, companies are using a polyurea basecoat. Many of these companies advertise saying these coating are 5 times, 6 times, or even 10 times stronger than epoxy. These advertisements are misleading and fail to discuss what makes their polyurea coatings so much stronger

The strength that is being referred to in regards to polyurea comes from the coating’s flexibility. The elongation for many polyurea coatings is around 300%, while many epoxies only have an elongation around 4-5%. We do use an epoxy coating for some of our applications with an elongation at around 150%, which is extremely flexible for an epoxy. Outside of flexibility epoxies and polyurea have a lot of similarities. They have good abrasion resistance, chemical resistance, and can withstand impact from heavy objects.

The drawbacks that come with polyurea are the inability to introduce water to the coating during the curing process and in many cases the inadequate adhesion due to the coatings quick cure rate. In Ohio, many times when installing garages, we get a lot of surprise rain that comes in on us and this is one of a few reasons we choose to use epoxy for most of our garage installs. With polyurea any dampness or excess moisture in the concrete can cause that coating to foam up and ultimately fail. We’ve heard of companies testing with a moisture meter to check the moisture in the concrete, which is great for that day and that moment, but won’t help if a heavy rain pops up when the time comes apply the coating. As an example, recently we were installing a garage floor and it started to rain on us and we got a little bit of water on the front part of the garage. Thankfully we were installing a moisture insensitive epoxy, which allows up to apply the epoxy over a damp surface without and issues.

A lot of the epoxies we use are moisture insensitive, and while we still can’t coat over standing water, does enable us to coat over a damp surface without any concerns of the coatings bonding to the surface. Moisture alone is a large deciding factor for why we choose to use epoxy over a lot of polyurea or polyaspartic when we’re putting them directly over the concrete. Polyaspartics are a fantastic top coat, but we don’t believe that they’re always the best coating for a base coat being applied directly over concrete.
On the commercial side of our installations, we always look at it through the customer-specific needs. We might add additional coats for their facility, whereas for residential, we generally only install 2-3 coats. Commercial and industrial facilities will be subject to much heavier traffic such as forklifts, heavy cart traffic, harsh chemicals, and other daily abuse. We want to make sure the coating is going to be thicker and designed for the heavier daily traffic and in doing so we may be required spec flooring system with numerous additional coatings which can take take 3 or 4 days to install. It’s important to do your research to make sure that these floors are going to be acceptable for your specific installation prior to the project.
By no means are polyurea coatings bad. We simply believe that are not the best coating for all uses and shouldn’t be used universally. Like any coating, polyurea has its strengths in some areas while weak in others. Knowledge of the different types of coatings, where to apply them and how they can be combined for certain systems will ultimately provide the right floor for any client!

If you have any further questions, we have some additional information on our site. You can also reach out to our team. We’ll be more than happy to get back with you and address any questions you may have.

You hear companies talk about those DIY epoxy kits, to stay away from them, and that they all fail. At Columbus Epoxy Flooring we agree with them completely, but why exactly are these DIY kits a bad option and what causes them to fail?

The low cost of the DIY option is appealing but as with most decisions in life, price isn’t everything and floor coatings are no exception. To start off, the epoxy coatings you find in the big box stores are a water based epoxy with only a 50% solids content and perform more like a paint. In the coatings world, solids content can help to determine the strength of the coating as well as the final thickness. When coatings are applied the thickness is measured using WFT (wet film thickness) and DFT (dry film thickness). To help understand further, the DIY kits specify that you apply the coating at around 7-8mils (1 mil= 1000th of an inch). 7-8mils is the WFT (wet film thickness). These coatings however, are only 50% solids, meaning 50% of the applied thickness will evaporate, leaving a final DFT (dry film thickness) around 3.5-4 mils. Professionals prefer to use 100% epoxy for the strength and the high solids content. These coatings are applied around 12-16 mils per coat to create a much thicker and stronger surface for the final outcome.

Thickness and higher solids content is only one reason industrial grade epoxies and other coatings are stronger. The coatings professional use also contain additives along with different chemistries all together which allows them to hold up against harsh chemicals, impact from heavy objects, daily abrasion, and provide protection from UV light. It’s also important to understand that not all coatings are created equal. In the professional floor coatings space we must use a variety of different coatings such as; polyureas, polyaspartics, 100% solids epoxies, water based epoxies, aliphatic and water based urethanes, novalac epoxies, MMA (Methyl Methacrylate) and many more. All these different chemistries are designed and engineered for their own purpose, and understanding why these coatings should be used for different purposes helps installers to provide the optimal solution that is right for our client. Part of our process to help find the right coating solution includes asking a number of questions to help determine what chemicals will be used on the floor, what daily traffic the floor will experience, how much downtime is allowed for the installation process that includes curing schedule after the floor has been installed.

The difference in chemistry of industrial coatings vs DIY is only part of why DIY coatings fail. Proper floor preparation contributes largely to the success of an installation and is the most important part for all coating applications. Epoxy coatings that are designed to be applied at a thickness around 4-40 mils must be prepped leaving a CSP (Concrete surface profile) of 3-5. A CSP of 3-5 can be achieved by diamond grinding or shotblasting. Many DIY epoxy kits recommend acid etching to clean the concrete and create a porous textured surface. Acid etching can generally only achieve a CSP 1. Acid etching can also leave an acidic residue behind and if not properly cleaned will further weaken the bond of the coating to the surface. Regardless of preparation method, a thorough cleaning of the floor is also required to remove any loose dust and other debris that may affect the bond of the coatings to the concrete surface.

All epoxy coatings are designed to be applied a certain way and any incorrect method may also cause failure of the project. Because DIY epoxy kits are generally 50% solids they must only be applied at a certain thickness. The thickness specified is only 3.5-4 mils or 250 square feet per mixed gallon. If these floor coatings are applied much thicker, any solvent that is contained within the epoxy will be unable to evaporate causing the coating to foam and ultimately fail. When working with any coatings you must be familiar with technical data and thoroughly understand how the coating should be applied to assure a successful installation.

Conclusion
Our professional Team has spoken with many people who attempted a DIY epoxy coating projects only to experience a lot of wasted money, headaches, frustration, and see all their hard work fail in a matter of months. We want to make sure all of our clients don’t have to experience these frustrations when looking to have a floor coating installed. Our team is trained and thoroughly understands how to successfully install resinous flooring to provide a solution that is right for our clients. If you have any questions or would like us to look at a potential project for you, please give a call at 614-470-2649 and we’ll be happy to help!

 

 

References:
DIY epoxy application method and thickness.
https://www.rustoleum.com/-/media/DA74ED5C0FAC47AEAD3074F3522BA4CA.ashx

Why to not acid etch.
https://www.dur-a-flex.com/tech-tips/avoid-preparing-concrete-with-acid-etching/

About CSP (concrete surface profile).
https://www.runyonsurfaceprep.com/how-rough-should-my-concrete-surface-be-for-a-proper-coating/

https://www.tccmaterials.com/wp-content/uploads/2020/06/ConcreteSurfaceProfiles.pdf

Choosing the “right” coating to coat a concrete floor is critical.  The right selection could add more life to the process with less maintenance, while picking a wrong one could lead to significant problems, including total failure.  These days there is a lot of discussion about the two most popular coatings available – epoxy and polyaspartic.  Both have significant qualities and many installers have chosen one or the other and say “Ours is Best!”  

You might think that since our name is Columbus EPOXY Coatings that we believe that epoxy is the best choice, period.  So, you might be surprised to hear that our view is: IT DEPENDS!  Each coating has its benefits and each can do a great job – with long life, slip-proofing and all the other qualities that a customer want.  

We Do Our Homework BEFORE Recommending a Coating Type 

Frankly, some installers are more interested in getting to a payday as fast as possible, avoiding the time and expense for the appropriate necessary to understand different types of coatings, specifications and purpose. Instead, one type of coating is chosen for every job.  Some product suppliers support this practice. A minority or product suppliers may offer “a one solution fits all” product to sell more product while their unsuspecting contractor client (often new to the trade) lose credibility and long-term, repeat business. 

Our view is different, we care enough to do our “homework” thoroughly.  We believe that our customers don’t care what coating we install as long as it’s the very best choice to meet their specific needs.  Before we recommend anything, we do a complete on-site analysis and ask a lot of questions to find out HOW your space is used and WHAT types of conditions the coating has to withstand.  

Our reputation and the trust we’ve earned with repeat customers is paramount to our foundation.  It’s a lot more important for us to be thorough and give each customer the right product/installation than it is to make a “quick buck.”   We understand that long-term quality equates to increased, long-term relationships and revenue. 

We study any and all coatings as they come on the market to make sure that we know which coatings are better suited for different environments.  Knowing how the space will be used – including cleaning – is an integral part of installing an efficient and effective coating. 

Surface Preparation

Surface preparation prior to applying a coating is one of many critical elements required for a good installation -, regardless of what type of coating is to be applied – for a successful installation. It’s imperative to ensure that the surface is profiled and ready to accept and ensure bond regardless of the coating is to be applied.  

Once we take the steps necessary to mechanically prepare the floor thoroughly, the installation will move forward.  We have the ability, technology, and trained crew to efficiently prepare floors prior to coating and to follow all the steps needed to provide the best results with minimal dust.  

Epoxy and Urethane Coating Systems vs. Polyaspartic Technology

Epoxy and Urethane Coatings

Epoxy and other resinous coatings normally consist of two elements: epoxy resin and a hardener, a catalyst that causes a chemical reaction that creates cross-linking of the elements as it cures. After the epoxy coating is applied, it is allowed to set up or cure.  A coating process will most often consist of 3 separate coats of varying types of product suitable for the environment. 

A typical installation normally requires a covers a 3-day process period for full curing. The result is a durable, tough plastic coating that provides durability, long life and which while resisting abrasion, impact, and chemicals.  

Primary Uses

Epoxy floor and resinous coatings are used, along with various resinous fillings on minor gouges and cracks, to extend the life of concrete floors in warehouses, logistic centers and other locations that are subjected to lift truck and other light traffic as well as medium to heavy foot traffic. These coatings have the ability to stand up very well to chemicals, oils, and cleaners.  Additionally, Novolac epoxies can even guard against sulfuric acids commonly found in battery changing stations

A specific variant – fusion bonded epoxy coating technology – provides corrosion resistant which makes it very popular in oil/gas and water/wastewater usage to protect pipelines from corrosion. 

Because this coating provides two layers of protection, it is more tightly cross-linked and less permeable, offering excellent substrate protection, chemical resistance, and hardness for heavy industrial and environments where industrial acids are used in industrial processes. 

However, organic acids, like nitric acid, which is used in food production, can damage epoxy and urethane coatings.

Polyaspartic Coatings 

Polyaspartic coatings is a are a relatively new technology, a hybrid coating type that has become very due to the speed of its curing process.  Polyaspartics often provide an excellent top-coat.

This technology offers very good color and gloss retention. It performs well as a top- coat while providing better versatility to lower temperature cure cycles.  Polyaspartics are also UV stabile. 

Primary Uses

It is used for exterior concrete where faster installations are required.

Quicker Drying Time and Other Benefits

Polyaspartic coatings have become popular because the base chemistry can be manipulated to suit varying applications – quick cure times help provide for a faster installation turnaround, time resulting in less downtime to a customer. 

Summary

The choice of coatings is a major consideration in how we will quote and plan the job.  The coating type we recommend will be the best choice for durability and long service life.  We don’t just do the quickest and cheapest work, our work is designed to stand the test of time and use.

Various coating technologies have their place and Columbus Epoxy Flooring will recommend the best system in terms of durability, resistance to traffic, chemicals, cleaning and cost effectiveness.  We work hard at finding the right solution because our customers depend on us and we appreciate and depend on them!