Before we embark on the process of installing epoxy flooring, it is essential to conduct a series of
meticulous tests and preparations to ensure a durable and long-lasting result. These preparations are
crucial to guarantee that the epoxy adheres effectively to the concrete substrate and performs
optimally. Here is an overview of the key steps involved:

1. **Moisture & RH Testing :**
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Moisture is a significant factor that can affect the bond and long-term performance of epoxy flooring. Excessive moisture in the concrete can cause delamination, blistering, and premature failure of the coating system. To accurately assess slab conditions, we use multiple evaluation methods, including surface moisture meters and in-situ relative humidity (RH) testing per ASTM F2170. RH testing provides a reliable indication of the moisture condition within the concrete slab, not just at the surface. By combining these tests, we obtain precise data on whether the substrate is within acceptable limits for epoxy application. If elevated moisture is detected, we implement appropriate mitigation strategies such as vapor barriers, epoxy moisture-control primers, or alternative resinous systems designed for damp substrates.

2. **Concrete Hardness Testing:**  

The hardness of the concrete substrate is another vital consideration. Epoxy adheres best to concrete with a specific hardness, typically measured using the Mohs or Shore D scales. We conduct hardness tests to evaluate the existing concrete's suitability for epoxy application. In cases where the concrete is too soft or too hard, we may need to adjust our preparation and epoxy formulation accordingly.

3. **Grinding for Concrete Surface Profile (CSP):**
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Achieving the correct Concrete Surface Profile (CSP) is critical to ensuring long-term adhesion and performance of epoxy flooring systems. CSP refers to the measurable roughness, texture, and porosity of the concrete substrate, typically classified using the International Concrete Repair Institute (ICRI) CSP scale ranging from CSP 1 (nearly smooth) to CSP 10 (very rough, achieved with heavy scarification or shot blasting). Each epoxy or resinous flooring system has manufacturer-recommended CSP requirements, which correlate to the coating’s film thickness, viscosity, and bonding mechanism.To establish the appropriate profile, we utilize surface preparation methods such as planetary diamond grinding, shot blasting, or scarifying, depending on the target CSP. For example, thin-mil epoxy coatings generally require CSP 2–3, whereas thicker self-leveling epoxies or urethane mortars may require CSP 4–6. During this process, the top layer of paste, laitance, weak concrete, and contaminants—including oils, curing compounds, adhesives, or prior coatings—is mechanically removed. This not only creates the correct surface roughness but also exposes structurally sound concrete, ensuring both mechanical interlock and chemical adhesion.Proper surface profiling is validated by comparing the prepared surface to ICRI rubber comparator chips or by using profilometry tools for more precise measurement. Failure to achieve the specified CSP can lead to insufficient adhesion, osmotic blistering, or premature coating delamination. By tailoring the surface preparation method to the resin system and project conditions, we optimize coating bond strength and system longevity.d chemical adhesion. Proper surface profiling is validated by comparing the prepared surface to ICRI rubber comparator chips or by using profilometry tools for more precise measurement. Failure to achieve the specified CSP can lead to insufficient adhesion, osmotic blistering, or premature coating delamination. By tailoring the surface preparation method to the resin system and project conditions, we optimize coating bond strength and system longevity.


4. **Seamless Epoxy Floor Application:**
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Once moisture levels have been assessed, concrete hardness verified, and the surface prepared to the specified Concrete Surface Profile (CSP), the substrate is ready for epoxy application. At this stage, proper material handling and installation techniques are critical to achieving a seamless, high-performance floor system.The epoxy resin and hardener components are proportioned and mechanically mixed using low-speed mixing equipment to ensure thorough blending without entraining excessive air. Accurate mixing times and ratios are strictly maintained, as deviations can result in improper curing, reduced mechanical properties, or surface defects. Once mixed, the material is immediately transferred to the floor to minimize pot life issues. Application methods vary depending on the system design. For thin-film or primer coats, the epoxy is typically applied using rollers or squeegees and back-rolled to ensure uniform coverage. For high-build systems, notched squeegees or gauge rakes are used to control film thickness, followed by spike rolling to release trapped air and achieve a smooth, pinhole-free surface.Multiple coats are often required to meet performance and aesthetic objectives. A primer coat promotes adhesion and seals residual porosity in the concrete. Intermediate coats may incorporate decorative aggregates, color flakes, or quartz to provide texture, slip resistance, or design effects. The final topcoat is selected based on project requirements—options include high-wear aliphatic urethanes, UV-stable polyaspartics, or chemical-resistant novolac epoxies.Throughout the process, ambient and substrate conditions such as temperature, relative humidity, and dew point are monitored to ensure compliance with manufacturer specifications and ASTM standards. Proper cure times are observed between coats to avoid intercoat adhesion failures. When executed correctly, the result is a seamless, monolithic epoxy flooring system engineered to deliver long-term durability, chemical resistance, and aesthetic appeal.

5. **Curing and Finish:**

After epoxy application, the floor is allowed to cure for the specified time, which typically involves a
waiting period before it is ready for foot traffic or heavy use. Depending on the project requirements,
we can also add various finishing touches, such as slip-resistant additives, decorative elements, or high-
gloss finishes to enhance the floor & functionality and aesthetics.

In conclusion, the process of installing an epoxy flooring system is far more than simply applying a coating. It begins with comprehensive testing for moisture content, pH, and concrete hardness, ensuring the substrate is suitable for long-term adhesion. This is followed by precision surface preparation, including mechanical grinding and profiling, to achieve the correct Concrete Surface Profile (CSP) as specified by the coating manufacturer and industry standards. Only once these critical parameters are verified do we proceed with the application of the seamless epoxy floor system, carefully mixed and applied in multiple stages to deliver the desired thickness, aesthetics, and performance. These meticulous steps create a durable, chemically resistant, and visually appealing flooring solution engineered to withstand years of service.Choosing the right contractor is just as important as choosing the right system. CD Construction Services combines technical expertise with hands-on experience, ensuring every project is executed to the highest industry standards. Our team is trained in ASTM and ICRI protocols, uses state-of-the-art preparation equipment, and selects only proven resinous systems tailored to each client’s needs. Beyond technical ability, we pride ourselves on clear communication, professionalism, and a commitment to delivering floors that exceed expectations in both function and appearance. When you partner with CD Construction Services, you’re not only investing in a floor—you’re investing in peace of mind. Our focus on quality control, moisture mitigation, and surface profiling ensures that your epoxy system is installed correctly the first time, minimizing costly callbacks and maximizing lifecycle value. Whether it’s a residential garage, a commercial facility, or an industrial space with demanding performance requirements, we provide solutions that are robust, long-lasting, and backed by our reputation for excellence.
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