Up to 500 square feet at 9.7 mils Dry Film Thickness. Up to 240 square feet for 20 mils Dry Film Thickness. Most industrial floors apply at 16-20 mils Dry Film thickness. A normal coat of water-based epoxy would coat at 1.5-2 mils Dry Film Thickness. A ½ kit will cover up to 250 square feet at 9.7 mils Dry Film Thickness.
We recommend patching all cracks prior to coating. Due to the fact that mortar joints/saw cuts are engineered for movement Epoxy-Coat does not recommend patching them prior to coating. All holes larger than ¼” should be patched prior to coating. All cracks can be patched (12 hours prior to coating) with a flexible, adhesive (paintable) acrylic caulk. Epoxy-Coat sells this product or you can purchase it at your local hardware store. Simply caulk the cracks and remove the excess with a tape blade. Holes larger than ¼” can be patched by Epoxy-Coat. Epoxy-Coat is 4x stronger than concrete so it is perfect for patching. You can patch holes or rough concrete in 2 different ways:
Apply Epoxy in a normal application. Do not back-roll in the rough/hole areas. This will only work on rough areas or holes which are not throughout the concrete (so the coating will not sink through the concrete when patched).
Mix Epoxy with a fumed silica (available through Epoxy-Coat), this will give a thicker viscosity and can be used to patch any and all rough areas/holes/joints at any thickness or size. Epoxy will have to be applied after this patchwork is complete.
The most important differences between floor coating epoxies are listed below:
Epoxy-Coat is a Cycloaliphatic 100% solids epoxy. This is a term used to describe the volume solids in a coating system. It is what is left over after the product dries. 100% solids yields 100% dried material after the coating fully dries. 50% volume solids yield 50% of the thickness after the coating fully dries. Most epoxies are 30%-40% volume solids. If you wish to compare the thickness after dried application between Epoxy-Coat and normal epoxies you would need 2.5x the gallons to equal exactly the thickness of 1 gallon of Epoxy-Coat.
It is a type of epoxy. Just like there are types of automobiles that perform differently (and vary in cost) so do epoxies. Not all epoxies are the same. If you wish to apply a high performance floor coating, you would want a 100% solids epoxy (to achieve a thickness suitable for proper aesthetics and durability), a high abrasion resistance, a product that would be resistant to yellowing or fading over time, high gloss, highly chemical resistant, impact resistant, 0 VOC’s (Volatile Organic Compounds) for low odor and safety in application in odor and VOC sensitive environments.
0.5 coefficient of friction is common acceptance in general floor areas and .8 on wheelchair ramps. The Elco meter test equipment can test Unit of force/weight of object. The Osha (Occupation Safety Health Administration) says a safe slip resistance as specified by 1910.68 is .5 coefficient of friction. Additional floor test specifications by ADA:
0.6 flat surface
0.8 ramped surfaces
As defined by ADA accessibility guidelines (ADAAG)
All concrete moves. Mortar joints/saw cuts are engineered to allow for the movement of concrete. Cracks are the cause of more movement than the mortar joints/saw cuts will allow for. Due to this, cracksmortar jointssaw cuts can be patched but there is no guarantee that they will not move in the future more than the patching will allow for, therefore causing a crack in the epoxy patch. Generally, this will simply be a small crack that will not chip or peel from the concrete.
Epoxy-Coat can be coated over existing paints/coatings by simply making sure the existing coatings are cleaned, sanded (80-100 grit) and bonding. All areas that are not bonding must be diamond ground to remove loose coatings prior to Epoxy-Coat application.
Using a gas torch burn the hairs from the floor prior to coating Coat the floor with first coat of Epoxy-Coat, wait 24 hours and sand vigorously with an industrial sander (80 grit), apply a second coat and flake the floor. Note: If you don’t flake the floor you may still see traces of hairs so it’s important to apply at least the minimum of flakes provided in a normal kit. Ordering an extra 1-2 lbs of flakes for a 2.5 car garage would be a good idea.
Simply remove sealers/waxes/contaminants/nails and use our flexible acrylic caulk to patch the seams and holes prior to coating. As long as the wood is clean and has a texture to it, sanding won’t be necessary.
Most floor coating epoxies are not Cycloaliphatic 100% solids. They are the most expensive to manufacture. They can cost up to 4x the amount of other epoxies to manufacture. Epoxy-Coat is the same quality of epoxy as is used in the most demanding industrial / commercial floors. In fact approx. 60% of industrial / commercial floors use a less quality Aliphatic 100% solids epoxy in their applications.
You can be assured that with over 35 years of experience in concrete floor coating, epoxy-coat is the only kit of its kind offered to the end user for demanding concrete or wood floor coating applications