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How to Prep Concrete Flooring for an Epoxy Coating

Epoxy flooring has several advantages over other flooring options when it comes to choosing a flooring surface for garages, machine shops, breweries, and industrial facilities. Sometimes referred to as resinous flooring or seamless flooring, epoxy is:

  • extremely durable
  • functional for a variety of applications
  • easy to clean and maintain
  • incredibly resistant to many chemicals including oil, solvents and acids
  • stands up to wear-and-tear from machinery, pallet jacks, forklifts, and vehicles

Although the epoxy flooring process is fairly fast and offers a minimal disruption to workflow, the underlying concrete surface does need to be properly prepped before the epoxy coating is applied. The coating’s integrity and performance may be compromised if the concrete isn’t sufficiently prepared before the epoxy coating application. Prepping the concrete first ensures that the epoxy coating will properly adhere to the surface to create a long-lasting flooring system.

Below we’ll discuss two of the most common epoxy flooring preparation methods and the best equipment to execute these methods:

Concrete Grinding For Epoxy Coating Preparation

workers using concrete grinder and dust collector to prep floor for epoxy coating

One of the most common ways to prepare a surface for epoxy is to remove deposits and coatings from the concrete and create a rough texture for optimum epoxy adhesion. This can be accomplished with a traditional hand-held angle grinder. However, a concrete floor grinder will allow you to prep a larger surface area much faster. Equipped with the right diamond-coated blades, concrete grinders roughen the surface more easily, efficiently, and evenly. Once the surface is cleared of debris, the epoxy coating can be applied for a faster turnaround time.

The HTC 450 Grinder, one of the most user-friendly and versatile models currently available, employs three counter-rotating grinding heads to properly prepare surfaces for epoxy coating. A built-in digital counter tracks the time spent on grinding and prepping the surface, while its innovative floating grinding hood actively responds to floor irregularities to improve dust extraction. The HTC 450 is perfect for residential and smaller commercial settings.

Slightly bigger than the HTC 450, but still compact, the HTC DURATIQTM T5 Grinder is perfect for a variety of larger residential and commercial grinding jobs. The dustproof, hermetically sealed grinding head and electrical enclosure increases the service life of its components and improves grinding precision. The T5 model also includes a removable weight kit that increases the grinding pressure for greater surface treatment as needed.

Easy to maneuver in a variety of settings and spaces, both the HTC 450 and T5 models allow operators to easily separate the motor and chassis and collapse the grinders for easy transport.

Shot Blasting Concrete to Prep For Epoxy Floor

Shot blasting is another effective method for preparing concrete floors for epoxy application is. This procedure blasts the surface with steel beads shot at high velocities to remove adhesives, mastic, and other coatings from the concrete. These blasts also roughen the concrete surface to help maximize epoxy adherence. Each blast is confined to an enclosed chamber that recovers any reusable shot and separates dust—this unique process helps limit the amount of dust and airborne contaminants.

Shot blasting is extremely effective at removing residue from concrete floors, and it can be the better option when the existing floors are uneven or pitted. However, there is definitely a learning curve when it comes to using a shot blaster, which may make it a better choice for experienced floor prep contractors.

Compact and extremely portable, the Blastrac 1-8DM shot blasting system is a great floor preparation tool for smaller jobs such as garages, breweries, showrooms and retail stores. Its manual travel speed and smaller blast pattern make it an ideal choice when operators have to treat confined spaces or work around areas that feature vehicle lifts, permanent equipment, or other obstructions.

Preparing concrete for epoxy is a messy task that can create a significant amount of dust. When planning your job, consider renting a concrete grinder package that also includes a high-quality dust extractor and air scrubber for a cleaner and safer project. Still have questions? The floor prep experts at Factory Cleaning Equipment can help you take the guesswork out of choosing the right concrete grinder or shot blaster for your application, whether it’s a residential garage or a manufacturing facility. Contact us today!

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