Epoxy mortar flooring is a type of epoxy resin flooring and is widely used in floor construction. What are the standard construction procedures for epoxy mortar flooring?
1. Floor Surface Preparation Before Coating
Purpose: To clean the concrete base and ensure strong adhesion of the epoxy floor coating.
All oil stains on the cement floor must be thoroughly removed until the surface is completely grease-free.
Any damp areas on the existing floor must be fully dried before construction to improve the adhesion of the epoxy floor.
Uneven surfaces, cement lumps and loose cement residue shall be ground flat with a floor grinder, followed by complete dust removal.
Prior to epoxy construction, concrete defects such as depressions, pits, honeycomb pitting and expansion joints shall be repaired by spot and full trowel application of epoxy mortar (epoxy resin mixed with quartz sand and quartz powder). After curing, grind the repaired areas and clean up dust.
For existing floor cracks, cut the cracks into a V-shape with an angle grinder first, then fill and level them with epoxy mortar. The finished epoxy floor shall be seamless overall.
2. Primer Coating
Purpose: To seal capillary pores and enhance bonding strength.
Primer application can only start after the repaired areas are fully cured.
Pour Component B into Component A in the specified mixing ratio, stir with a portable electric mixer for about 3 minutes. Roll the mixture evenly over the whole floor with a short-nap roller; apply to corners and joints with a short-nap roller or brush.
Curing time depends on site temperature, generally 6–12 hours. Subsequent work can only proceed after the primer is fully cured.
The primer shall be rolled evenly with no material accumulation and no missed spots.
3. Epoxy Intermediate Coat Construction
Purpose: To increase floor strength and improve surface flatness.
Mix Component A and Component B of the intermediate coat in the specified weight ratio. Stir thoroughly with a dedicated portable electric mixer at 300–500 rpm for about 3 minutes, while gradually adding Component C and mixing evenly.
On the cleaned base surface, trowel the mixed material evenly over the primer layer with a trowel; use a small putty knife for corners and joints.
Cure for generally 24 hours depending on ambient temperature. After full curing, inspect the floor for uneven areas. Grind with an angle grinder and remove dust if necessary before proceeding to the next process.
4. Epoxy Topcoat Construction
Purpose: To further enhance floor strength, wear resistance and overall appearance.
Mix Component A and Component B of the topcoat in the specified weight ratio. Stir thoroughly with a dedicated portable electric mixer at 300–500 rpm for about 3 minutes, while gradually adding Component C and mixing evenly.
On the cleaned base surface, trowel the mixed material evenly over the base layer with a trowel; use a small putty knife for corners and joints.
Determine curing time according to site temperature. After full curing, inspect the floor for uneven areas. Grind with an angle grinder and remove dust if required before completion.
