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A Look Into Concrete Surface Prep

Updated: Jan 10

We make sure to meticulously prepare our client's floors in order to achieve a flawless outcome. Surface prep starts with grinding the concrete mastic. Mastic is the dull, brownish grey coloring on the surface of the concrete. Using industrial strength grinders, we grind off the mastic with diamond bits in order to reach the aggregate of the concrete. Doing this ensures that our epoxy will adhere to the surface so that there is no worry that it will ever peel.

Concrete Grinding Process

Grinding is a crucial step to create a smooth and porous surface for the epoxy to adhere to. These are the steps:

  • Choose the Right Equipment: We use a Husqvarna PG 540 which is a commercial grade concrete grinder. This machine makes it quick and easy to grind off any existing coatings and/or concrete mastic

  • Coarse Grinding: Starting with a coarse diamond abrasive, the machine levels uneven surfaces and removes imperfections.

  • Fine Grinding: We then switch to a finer grit for a smoother finish. This step is crucial for maximizing epoxy adhesion.

  • Surface Vacuuming: After grinding, we vacuum the surface to remove dust and debris. A clean surface is essential for proper epoxy bonding.

Grinding With The Husqvarna PG 540

Crack Patching

Almost all garage floors have cracks, holes, and divots in the concrete. We use a variety of patching compounds to fill in cracks in the concrete. After we finish our patch work, we are able to achieve a smooth and even surface.

These are the steps:

  • Crack Preparation: Clean out cracks using a wire brush or compressed air. Open up the cracks with a "crack chaser" blade so that the material will completely fill into the nooks and crannies. Remove any loose material with a vacuum to ensure a strong bond with the patching material.

  • Choosing the Right Filler: We use a high-quality epoxy or polyurea-based patching compound suitable for all different types of cracks. These compounds offer excellent adhesion and durability.

  • Application: Apply the patching compound using a putty knife or trowel, ensuring it is level with the surrounding surface.

  • Sanding: Once the patching material has cured, sand the repaired areas to create a smooth transition with the rest of the floor.

After curing, the patching is sanded down to achieve a smooth surface

Final Surface Cleaning

Dust Removal: Before applying the epoxy coating, we thoroughly clean the surface again to remove any remaining dust or debris. A clean surface is essential for a flawless finish!

Left side has been vacuumed and right side still has dust

Why Is Surface Prep So Important?

Proper concrete surface preparation is the foundation for a successful epoxy flooring application. By carefully assessing the concrete, using the right tools for grinding, and diligently patching any imperfections, you can ensure a seamless and long-lasting epoxy floor. Remember, attention to detail during surface preparation will pay off in the form of a beautiful and resilient epoxy finish that stands the test of time.

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