1. Safety Precautions
Before embarking on your DIY garage epoxy flake flooring project, it’s crucial to prioritise safety. Begin by thoroughly reading the chemicals manual, ensuring you understand the properties, potential hazards, and safe handling of each product.
During the process, ensure adequate ventilation and use protective gear to prevent the risk of inhaling harmful dust or fumes. In case of any spillage or washout, have a spill kit handy and know how to use it properly.
If your project involves hot work, like grinding, take precautions to avoid fires and burns. Be mindful of exposure to dust, especially with the newly introduced silica dust regulations in NSW.
It’s essential to barricade your work area to prevent unauthorized access, protecting the public from any potential hazards. Only use tagged electrical machines that have been inspected and deemed safe.
Never operate machinery without appropriate training, particularly when dealing with hazardous materials. Wear protective clothing, including gloves and safety glasses, to shield yourself from chemical spills or dust exposure.
Remember to diligently read all product labels to ensure you comply with material and waste disposal regulations. Using the right tools not only ensures the job is done well but also contributes to safety.
2. Tools and Materials Needed
For a smooth and successful application of garage epoxy flake flooring, it is indispensable to have all the necessary tools and materials at hand before commencing the project. Interruptions in the epoxy application process to procure missing items can negatively affect the quality and consistency of the work, leading to a less than optimal final result. This scenario could also create undue stress, increasing the potential for errors and subsequent issues. The following sections will walk you through the specific tools and materials required, ensure you have everything prepared and within reach before starting. This prior preparation will allow you to focus solely on the application, thereby promoting a high-quality finish and a stress-free process.
3. Preparing Your Garage Floor for Epoxy
To ensure a high-quality epoxy application, the best way to prepare your concrete floor is through diamond grinding. This method guarantees a thoroughly cleaned porous, and firm substrate ready for the epoxy application. Start by hiring a 250 mm walk-behind grinder from reputable rental companies such as Kennards Hire or Coates. Make sure to also hire a medium bond, 50 grit diamond discs which are ideal for medium-hard concrete.
If your concrete is soft and dusty, request a hard bond diamond disc. Conversely, for harder concrete, a softer bond diamond is required. Selecting the appropriate diamond tool is crucial in the diamond grinding process, as it enhances efficiency, saving time and money. If you’re unsure about which tool to hire, feel free to contact us, and we’ll be happy to assist you.
Grind the floor safely, ensuring all dirt, contamination, and any existing paint are thoroughly removed. After grinding, a thorough vacuuming is essential to remove dust, as dust acts as a de-bonding agent between the epoxy and the concrete.
Perform a water drop test to confirm you’ve successfully ground the floor. Also, consider watching this video that is showing us grinding a floor. Remember, the key to an optimal epoxy application is to achieve a clean, firm, and porous substrate.
4. Patching Cracks and Holes
Following the grinding process, it’s important to address any cracks and holes in your garage floor. To do this, we recommend using an epoxy-based patching compound such as Sikadur 33. Unlike cement-based repair materials, which can retain moisture for an extended period after application and compromise the epoxy coating, epoxy-based compounds ensure a dry and robust surface ready for the coating.
Ensure all imperfections are adequately filled and patched using the same compound. However, exercise caution when choosing unknown patching products or bogs, as they may not be compatible with your chosen epoxy material and could affect the quality and longevity of the coating.
For a visual guide on how to effectively patch your floor, consider watching this video. It demonstrates one of our projects where we patched multiple floor cracks prior to the epoxy coating application. The video should give you a clear idea of the process and the end results you should aim for.
5. Applying the Epoxy Base coat
Before mixing and applying the epoxy base, you should gather all necessary tools and materials within easy reach, including your spill kit. It’s critical to ensure that your working area is safely barricaded to prevent any disturbances throughout the process. Always check the floor temperature, relative humidity (RH), forecast and dew point to guarantee you’re within the optimum conditions for epoxy application as stipulated in the product’s data sheet.
To begin, mix a small amount of epoxy (less than 4 litres) according to your product’s mixing instructions and start cutting in all around the job where using a roller isn’t feasible. Using a paint tray, apply the epoxy with a 12 mm nap roller, ensuring coverage of 6-7 m² per litre. Make sure to de-fluff your roller sleeve prior to application and spread the epoxy evenly to avoid inconsistencies. Be cautious to avoid splashing epoxy on the walls and surrounding areas.
If you are working in a hot environment, consider mixing smaller amounts of epoxy to maintain control over the procedure. Once the epoxy is spread, put on spiked shoes and lay off the epoxy, aiming for a consistent 600-micron thickness everywhere. For this stage, products like Hychem Supafloor, Sikafloor 264, or EP100 from APC can be used. Do take note that EP100 is a self-priming epoxy, and depending on the condition of your concrete, a primer layer may not be necessary.
6. Applying the Flake Coat
You’re almost there! With your spiked shoes on, confidently tread on the wet epoxy base. Now comes an essential part – applying the flake coat. To get started, take a handful of flakes and broadcast them full to rejection. To get a perfect dispersion, throw the flakes upward, allowing them to spread evenly in the air before they settle on the floor. Be patient, don’t rush, and ensure you methodically proceed from one direction to another. For a standard double garage of up to 36 m², you will need approximately 15-20 kg of flakes. Once the flake broadcast is complete, lower the garage door. This step is crucial to prevent leaves and debris from blowing onto the floor. Finally, let the epoxy dry overnight. This rest period is crucial for achieving a flawless, durable finish.
7. Applying the Topcoat
The final step is applying the topcoat but before we proceed, we need to prepare the surface. Use a scraper to shave off any protruded flakes. This step is critical for preventing injuries from bare foot traffic. Once this is done, collect and dispose of excess flakes from the floor using a blower or a vacuum.
For the topcoat, it’s crucial to use a UV stable clear product like a polyaspartic or a polyurethane. We highly recommend using polyaspartics due to their thick film and high performance. Suitable products include Sikafloor 550PA or Sparta 60 from APC. However, be aware that polyaspartics cure extremely fast and require experience for proper application. If you’re in doubt, Sikafloor 359 au, Hychem Polyglaze NY, or Sikafloor PU can be used instead as they provide more working time. Two coats will be necessary for these alternatives to ensure proper coverage on your full flake floor.
Application of the topcoat should be carried out with a high quality 12 mm nap roller to avoid hairs in the topcoat. Make small mixes of less than 3 litres and apply evenly at a rate of 6-7m² per litre. It’s important not to apply too much product in each coat as polyaspartics and polyurethanes won’t cure if applied too thickly. Multiple layers may be necessary. Roll in one direction and lay off cross way. Do not use spiked shoes in this stage as you will leave punch marks on the floor.
8. Aftercare and Maintenance
Once your epoxy floor is installed and cured, proper aftercare and maintenance will ensure its longevity and keep it looking brand new. Regular cleaning is essential – dust or mop the floor daily and use a soft bristle brush or a microfiber mop for thorough cleaning. For stubborn grime, you can use a mild detergent mixed in warm water. Avoid using acidic or abrasive cleaners as they can dull the surface over time. To prevent scratches or gouges, place protective padding under heavy furniture or equipment. Repair any chips or cracks promptly to prevent moisture penetration and further damage. Remember, a well-maintained epoxy floor can last for many years, providing you with a durable and attractive surface.
9. Conclusion
In conclusion, the installation of an epoxy floor is a meticulous process that requires preparation, precise application, and proper aftercare. When done correctly, it can provide a highly durable and aesthetically pleasing surface that lasts for many years. At Atlas Coating, we’re dedicated to assisting you every step of the way. Whether you need guidance on product selection, help with installation techniques, or advice on maintenance, our team of experts is always ready to offer support. We are committed to ensuring that you achieve the best possible outcome for your flooring project. Feel free to reach out to us at any time.
10. Frequently Asked Questions
Q1: Is epoxy flake flooring slippery?
While the glossy, high finish of an epoxy floor may appear slippery, various anti-slip additives can be incorporated into the epoxy during installation to enhance grip and reduce slipperiness. These additives, also known as anti-slip media, are mixed into the epoxy coating and provide a slightly textured surface that reduces the risk of slipping, even when the floor is wet. The type of anti-slip media used can be adjusted to meet the specific needs of the area where the flooring is installed. For more detailed information on anti-slip solutions with epoxy, please click here.
Q2: How long does an epoxy flake floor last?
With proper care and maintenance, an epoxy flake floor can last up to 20 years or longer in a residential garage. Its longevity makes it a cost-effective option for homeowners.
Q3: Can I install epoxy flake flooring myself?
While it’s possible to install epoxy flake flooring yourself, it’s a complex process that requires precise measures and techniques. Professionals have the necessary experience and tools to ensure a smooth, even, and durable finish.
Q4: What colours or designs can i choose for my garage epoxy floor?
Epoxy flake flooring comes in a wide array of colours and designs to suit the aesthetic preferences of every homeowner. Whether you prefer a classic natural look, a bold and vibrant colour, or a custom design, the choice is yours. For an up-close look at our colour palette and design options, click here.
Q6: Can epoxy flake flooring resist oil and chemical spills?
One of the major advantages of epoxy flake flooring is its resistance to oil, gasoline, and other common garage chemicals. Spills can be easily cleaned up without causing stains or damage.
Q7: Can epoxy be applied on tile?
Yes, epoxy can be applied on tile. However, the process requires careful preparation to ensure proper adhesion. The For a detailed understanding of the process, you can visit this link or watch this video.