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.
Bare concrete floors constantly undergo a destructive process called dusting, where the top layer slowly breaks down into fine powder. This highly abrasive cement dust completely ruins valuable warehouse inventory and severely damages highly sensitive industrial machinery over time. By permanently encapsulating the porous concrete with our advanced resinous systems, you completely stop dust creation and secure a remarkably clean environment.
Assessing the Dust Problem for an epoxy floor installation
To firmly guarantee a dust-free floor that easily survives intense commercial traffic, the raw concrete must be heavily and properly treated beforehand. The absolute most common cause of commercial coating failure is terrible surface preparation. We spend significant time meticulously cleaning and treating the substrate, ensuring it is entirely free of industrial oils, old grease, and hidden dirt.
To firmly ensure permanent adhesion, we initiate the installation of epoxy flooring with aggressive mechanical surface preparation. Rather than utilizing ineffective acid etching, our highly trained teams operate heavy industrial diamond grinders. This massive equipment thoroughly profiles the hard concrete, securely opening its microscopic pores so the primer can instantly bite and heavily hold fast without ever peeling.
Industrial Grinding in the installation of epoxy flooring
Heavy diamond grinding is strictly required to forge a permanent, unbreakable mechanical bond between the raw slab and the liquid resin. As the powerful grinders safely strip away the contaminated top layer, they heavily leave a highly specific texture behind. This roughened surface strongly allows the specialized coatings to deeply penetrate the concrete, fiercely preventing any future peeling issues.
By effectively removing the weak, heavily damaged top layer of the warehouse facility floor, we permanently expose a rock-solid foundation. This vital process firmly ensures that the thick industrial coatings have a clean, highly reliable surface to adhere to. Proper mechanical grinding is the absolute true foundation of ensuring your new dust-free floor will survive decades of heavy abuse.
Fixing Concrete Before your epoxy floor installation
Our expert technicians flatly refuse to apply premium coatings over a broken or heavily compromised commercial foundation. During the extensive preparation phase of the epoxy floor installation, we carefully scrutinize the entire warehouse area for hidden cracks, deep pits, or crumbling spalls. Every single structural flaw must be permanently addressed to strongly ensure a flat, highly level finish.
We heavily utilize highly advanced, high-strength resinous fillers to seamlessly and permanently repair these dangerous structural imperfections. By meticulously patching every large crack and filling every deep hole, we completely restore the overall strength of the entire concrete slab. This mandatory repair step absolutely guarantees the final seamless surface is totally safe, perfectly level, and incredibly durable for forklifts.
Blocking Moisture in the installation of epoxy flooring
Commercial warehouse environments frequently suffer from severe moisture vapor transmission coming up through the porous concrete slab. This hidden moisture quickly leads directly to outgassing, which predictably causes terrible surface bubbles and catastrophic coating failure. To completely neutralize this massive threat, we always apply a specialized, deeply penetrating moisture-vapor barrier primer to heavily seal the entire floor.
This advanced moisture-mitigating primer acts as a permanent, completely impenetrable shield against intense underground hydrostatic pressure. Once the thick primer safely cures, it completely locks out dampness and keeps all trapped air firmly inside the concrete. This critical step strongly protects your industrial investment, heavily guaranteeing the thick resin layers above remain flawlessly bonded and incredibly smooth forever.
The Impact Base Coat during an epoxy floor installation
As soon as the necessary moisture barrier is completely set, we confidently apply a heavy, one hundred percent solids industrial base coat. This massive body coat heavily creates the essential structural thickness and safely delivers absolutely incredible impact resistance. It forms the incredibly tough core of the flooring system, heavily engineered to handle the harshest daily warehouse environments.
Because this incredibly thick base coat contains absolutely no shrinking solvents, it safely cures into a solid, unbreakable layer of protective armor. It fully ensures your seamless floor can flawlessly withstand massive pallet jacks, constant forklift traffic, and brutal daily wear. This dense layer of resin strongly provides the extreme durability that busy warehouse facilities truly require today.
Durable Finishes in the installation of epoxy flooring
Depending on your specific operational warehouse requirements, we proudly offer several highly durable decorative finishes to heavily protect your commercial space.
- High Traction Flakes: We broadcast tough vinyl chips directly into the wet base coat to add necessary slip resistance for worker safety.
- Safety Line Striping: We apply vibrant, high-gloss industrial pigments to instantly create highly visible designated walkways for heavy forklift traffic zones.
- UV Stable Clear Coats: We utilize highly advanced polyaspartic topcoats to strictly ensure your beautiful warehouse floor heavily resists dangerous yellowing from sunlight.
Final Review of the epoxy floor installation
Our meticulous industrial process completely ensures you quickly receive an exceptionally tough, easy-to-clean floor built to effortlessly last for decades. By heavily prioritizing exacting mechanical preparation, aggressive moisture mitigation, and utilizing the absolute strongest industrial resins, we guarantee a completely dust-free finish. Your damaged concrete will be permanently transformed into a brilliant, highly functional, resilient warehouse masterpiece.