An epoxy coating is a hard, durable material that is a blend of a polyamine hardener and an epoxy resin. The mixture creates a tough material used to enhance surfaces. Epoxy coatings are durable, chemical resistant, and adhesive to various surfaces. Their resistance to UV radiation makes them an excellent option for outdoor applications. They come in various types and serve different purposes. Here is everything you need to know about epoxy coatings.
Types of Epoxy Coatings
There are various forms of epoxy coatings:
100% Solid Epoxy
These epoxy coatings are made only from epoxy resin and hardener. They do not contain any solvents or volatile organic compounds (VOCs). Their properties include high durability and resistance to chemicals. They are suitable for commercial and industrial use.
Solvent Borne Epoxies
These types of coatings are mixed with solvents for adjusting a few different properties of the mixture. Adding solvents by a manufacturer will modify properties such as how viscous (thick / thin) the epoxy is, for ease in spraying or brushing and rolling the product. Another property is the evaporation rate, where slow evaporation makes for easier levelling of product, and avoiding dry spray if the product is being sprayed. Another feature of adding solvents is making the epoxy and the resin blend better together. Think of of these epoxies as “more optimized” by manufacturers! The characteristics include: High durability, good adhesion to surfaces, and chemical resistance. They are popularly used in areas with oil contamination like car parks and garages. Adequate ventilation is required during their application as they release volatile organic compounds.
Epoxy Flake Coatings
These coatings have decorative vinyl flakes in their coatings. They come in a wide range of colors and sizes and are known for creating an anti-slip surface.
Benefits of Epoxy Coatings
Epoxy coatings have numerous benefits:
- Durability: They have a strong layer that protects surfaces from damage and minimizes repairs.
- Resistance to Chemicals and Abrasions: Epoxy coatings have high resistance to chemicals, solvents, acids, and oils, and therefore offer adequate protection to surfaces.
- Aesthetic Appeal: The material creates a polished look that enhances the beauty of the environment. For these reasons, they are a preferred option for commercial spaces and industries.
Applications of Epoxy Coatings
Epoxy coatings have several applications like industrial and commercial flooring. Additionally, they are used to enhance the protection of concrete and as decorative flooring.
The Application Process
Here is a DIY homeowner guide on how to apply epoxy coatings. Establishing how much epoxy you’ll need is important, but, similar to how surfaces that are to be painted require proper scraping and primer products, the epoxy application procedure will also require plenty of prep aswell so the final product also sticks to the floor! This is so important that the floors be prepared well because these surfaces will be receiving foot traffic, and potentially also vehicle traffic.
Surface Preparation
Clean, Wash and Degrease
The first step is to prepare the surface by degreasing and removing any dust! Use plenty of TSP (Tri-Sodium-Phosphate) for any oil or dirty or greasy spots.
Sand and Grind
For an effective application, it’s important to ensure that the surface is a bit rough for the epoxy to stick. You need to sand down surfaces to enhance the adhesiveness of the epoxy. You’ll want to rent a “walk-behind” floor grinder tool with Diamond cutting heads. Check your nearby tool rental stores. When renting, ask for “medium” bond diamonds for concrete cutting. They’ll help you out. Also, for smaller and tighter spots, you will likely also want to get a 7” angle grinder with a wheel called a diamond cup wheel. Make passes in both directions on the floors, until you have a surface as rough as 60-80 grit sandpaper. This makes for a surface that epoxy will grip to. Does it feel smooth? If so, then it won’t grip. Rough? It’ll grip like a monkey grips a banana.
Patch and repair minor holes and cracks
Next patch cracks. Use an epoxy crack filler like Rustoleum Concrete Patch and Repair from Home Depot. Additional sanding / grinding should be done so that the entire surface, including the patch-repaired areas, are smooth and blend into one another.
Clean, Wash and Remove Dust
Next, don’t sweep, but vacuum! You can can also take a dark damp rag and place it on the concrete. If it pulls up gray dust, you need to vacuum again. Epoxy won’t stick well to smooth surfaces, or to dust, so we need to get rid of all the dust.
Final Moisture Check
A moisture check can reveal if the concrete will be too wet for applying epoxy. This might more-so be an issue if the concrete is more recently fresh, and is still curing. To do a moisture check, a sheet of 6 mil painter plastic can be used and taped down onto the concrete floor and left overnight, to see if condensation forms underneath. If there is condensation buildup on the underside overnight, the concrete needs to cure more (a little trick, brought to you by the owner of a St John’s painter company who also paint concrete floors). If the concrete floors are really fresh, it could need 30 days or more to fully evaporate the remaining moisture and really harden. Alternatively, an epoxy that is tolerant to some moisture, could also be selected.
Any final wiping in the preparation process should be done with an alcohol (like an Electronics Cleaner) to remove water moisture and dust. The alcohol won’t pose a problem to the upcoming epoxy as the alcohol evaporates water moisture. As you can see, the detailed and thorough preparation of surfaces in itself can be the most time consuming part of the project, for the end project to really adhere well and last a long time. By a similar token, if you need a thorough company to take care of any of your interior or exterior painting for a property of yours in or around Medicine Hat, Alberta, a trusted construction partner of ours we recommend, is the reputable Medicine Hat painter company Hatter Painters.
Application
Now, your surface is free from grease, dirt, and is more than adequately scuffed up / grinded up for excellent adhesion. Now, select high-quality tools like brushes, rollers, maybe even a sprayer. Now you can use a nap roller or a wide (3”-4”) painting brush preferably with natural bristles (instead of synthetic bristles) for a smooth finish.
Curing and Drying
The curing and drying of epoxy coatings are influenced by factors like the epoxy type used, humidity, and temperature. Applying a thin coat of epoxy is recommended to facilitate drying and prevent peeling.
Maintenance and Care
Proper maintenance and care are required for the longevity of your epoxy coatings. You can do this by routine cleaning of your epoxy-coated surfaces with soap and water. Additionally, check regularly for any damage. Lastly, repair cracks and damages immediately to ensure your epoxy coatings serve you for years to come.
Final Thoughts
Many industries and commercial settings prefer epoxy coatings due to qualities like strength, durability, and high resistance to chemicals. They are suitable for most surfaces due to their adhesion, flexibility, and protection against corrosion. Nevertheless, the beauty and low maintenance of epoxy coatings can only be retained by regular maintenance and immediate repairs in the event of any damage.