Concrete coatings are an excellent option to provide a new layer of protection and revive the appearance of your manufacturing facility flooring. But before a new floor can be applied, essential preparedness steps must be taken to ensure long-lasting, appealing results. Without a well-prepared surface, coating applications can take on a multitude of issues over time, including bubbling, corrosion, and complete separation from the original concrete flooring.
From epoxy to polyurethane, take a moment to discover the multiple preparedness steps for concrete coatings and why they’re essential to the longevity of your new flooring.
Epoxy Preparation Steps
To experience the long-lasting and highly-durable capabilities of an epoxy concrete coating, you must begin with a perfected surface. First, a thorough inspection of your facility flooring must be completed to identify any possible signs of wear and tear. Areas with extensive moisture, heavily damaged concrete, or previously applied paints and sealants can negatively affect the adhesion of the epoxy coating and should be repaired prior to application.
Next, the floor must be cleaned of any underlying oil and dirt buildup to achieve full adhesion of the epoxy coating. Heavy-duty cleaning agents and machinery are used to ensure a fresh, clean surface. As with most concrete coating applications, the final step is to then profile the existing concrete.
Profiling the concrete means to rough up the surface, creating evenly-spaced peaks and valleys for the coating to fill and form a durable, even appearance. The majority of epoxy coatings will use diamatic or diamond grinding to penetrate the concrete’s surface and enable a strong adhesion of the epoxy.
Polyurethane Preparation Steps
Manufacturing facilities that undergo heavy machinery or chemical operations are better suited for the flexible and chemical-resistant features of a polyurethane concrete coating. As with epoxy applications, several preparedness steps are necessary to successfully apply a polyurethane coating. Polyurethane is especially sensitive to humidity and moisture, so installation must begin with a moisture content test of the floor and interior warehouse location.
If the application area is overly moist, vapor can form underneath the coating to cause bubbling and detachment of the polyurethane. If the environment is overly humid, a humidity-durable coating such as epoxy may be a better option for the facility. Once your installer has confidently determined the moisture content of the area, it’s time to clean and repair the surface of any wear and tear.
Any surface contaminants and/or damage will further any issues of bubbling and corrosion following the application. The entire area must be reviewed for damage and any concerns must be repaired prior to concrete profiling. For polyurethane coating, shot blasting is an effective profiling method that discharges small steel balls to remove any deep surface contaminants and prepare the surface for coating. This process allows the polyurethane coating to strongly adhere to the concrete, effectively minimizing any issues of bubbling and corrosion later on down the line.
Novolac Preparation Steps
Constructed with a strong molecular structure, novolac coatings were designed to be heavily resistant to destructive acid and chemical spills. With a two-layer application process that provides intense durability, following all required preparedness methods is especially important when dealing with novolac coatings. As novolac is a variety of epoxy coating, the two share very similar preparedness methods.
Installation begins with a deep-clean and reparation of any significant damage. Surface contaminants such as oil or dust debris, deep cracks, or crumbling can induce bubbling or corrosion, dramatically impacting the results of a novolac application — and making the area susceptible to acids and chemicals. Once a clean surface has been achieved, the concrete must be profiled.
Profiling the concrete is the final step before applying a novolac coating. Since novalac requires a double-layer process, diamond grinding will penetrate the concrete deeper to remove any obstructions that could affect the curing process. The evenly profiled surface will help both layers of the novalac adhere properly to reveal a smooth and durable finish.
Urethane Mortar Preparation Steps
With its heavy durability, resistance to heat, and non-existent solvent odors, urethane mortar flooring is popular in food and beverage processing plants and industrial kitchens. Unlike polyurethane coatings, urethane mortar flooring can be applied in varying humidity and temperature levels. Plus, the coating dries quickly to aid in a rapid project turnaround.
As with all concrete coatings, the surrounding area will still need to be deep-cleaned and removed of any chemical or oil build-up to effectively adhere to the concrete coating. However, urethane mortar coatings require a suitable concrete profile before pouring the coating. Light shot blasting will help remove any remaining surface contaminants and provide a concrete profile suitable for the coating to stick properly and last for years to come.
Planning Your Next Steps?
From epoxy to urethane mortar applications, these critical preparedness steps are essential to the success of your new flooring project. A lack of preparation can easily sidetrack the desired outcome for your facility, and realistically, should be administered by a professional for top results. At Concrete Coatings of the Carolinas, we understand what it takes to provide a top-quality concrete coating. Contact us today to learn more about what we can do for your facility flooring.