Installing a high-performance epoxy floor is a precision-driven process that demands a balance of chemistry, heavy-duty machinery, and timing. While DIY kits exist, industrial-grade results require a technical approach to ensure the coating bonds permanently to the substrate.
At AK Level & Polish, we follow a strict protocol to ensure our installations last for years in the demanding environment of the GTA. Here is the professional workflow for a successful epoxy flooring project.
Phase 1: Surface Preparation (The Foundation)
A professional installation is 90% preparation. You cannot simply apply epoxy over dirty or smooth concrete.
- Mechanical Abrasion: We use industrial diamond grinders or shot-blasters to remove the “laitance”—the weak, top layer of concrete—and open the pores. This creates a CSP (Concrete Surface Profile) that allows the epoxy to mechanically lock into the slab.
- Cleaning: Every speck of dust must be removed via high-powered industrial vacuums. Any residual dust will act as a bond-breaker, leading to premature delamination.
- Repairing the Substrate: All cracks, pitting, and divots are filled with a specialized, low-shrinkage structural epoxy mortar. We also inspect and treat existing expansion joints to ensure a seamless look.
Phase 2: Priming and Sealing
Once the surface is clean and profiled:
- Applying the Primer/Base Coat: We apply a penetrating, low-viscosity epoxy primer. This layer is engineered to “wet out” the concrete and soak deep into the pores. This step is vital to prevent outgassing, where air trapped in the concrete escapes during the curing process and causes bubbles or “fish-eyes” in your finish.
Phase 3: The Build and Finishing
- Body Coat Application: Once the primer is set, we apply the main body coat. If you are opting for a decorative flake or quartz system, this is the stage where we broadcast the aggregates into the wet resin until it reaches saturation. This not only creates a beautiful aesthetic but also adds significant thickness and impact resistance to the system.
- Scraping and Sanding (If Applicable): For decorative systems, once the body coat cures, we scrape off excess flakes and lightly sand the surface to ensure a smooth, uniform texture before the final seal.
- Final Topcoat Application: This is the most technical part of the installation. We apply a high-performance aliphatic polyurethane or polyaspartic topcoat. Unlike basic epoxy, these materials are UV-stable (they won’t turn yellow over time) and provide an extreme shield against chemicals, abrasions, and heavy traffic.
Pro-Tips for a Successful Install
- Check the Moisture: Before starting, always perform a calcium chloride or plastic sheet test. If your concrete has high moisture vapor transmission, you must use a specialized moisture-mitigation primer, or your floor will eventually bubble and peel.
- Mind the Temperature: Epoxy is a chemical reaction. If it is too cold, it won’t cure properly; if it is too hot, the working time (pot life) is drastically reduced. We monitor the dew point and floor temperature closely to ensure a perfect cure.
- Don’t Skip the Profile: If the concrete is too smooth, the epoxy has nothing to grab. If you aren’t using industrial grinding equipment, the results will rarely last.
Why Choose AK Level & Polish?
A “flawless” floor is the result of years of experience in the specific concrete conditions of the Greater Toronto Area. Whether you need an industrial-grade warehouse floor or a high-end garage finish, we bring the right equipment and the right chemical systems to get the job done right the first time.
Thinking about upgrading your facility? [Contact AK Level & Polish today] to request a site assessment. We’ll handle the technical details—from moisture testing to topcoat application—so you can focus on your business.
Ready to see the results of our professional installation process? Browse our recent portfolio to see the transformation of various industrial and residential spaces.
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