Because the coatings take around 24 hours to cure completely, our installation goal is always to finish the job in one day. With the execution of our standard operating procedures, we ensure a quality installation with minimal down time for the customer.
1. PREPARE CONCRETE
2. APPLY BASE COAT
3. BROADCAST FLAKES
4. SCRAPE FLAKES
5. APPLY TOP COAT
6. ALLOW TO CURE
1. PREPARING CONCRETE
The preparation of the concrete is the most important part of the process. If the product can't make a solid bond with a stable base, it will lessen the likelihood of permanence. The concrete must be cleared of customer's belongings before any concrete preparation can begin. The first step is grinding of the surface to remove any previous paint, coatings or texture. This step is vital because it brings the concrete to a porous state to ensure sufficient bonding by the polyurea base coat. The grinding also opens up and exposes any underlying cracks. Cracks and divots are repaired using our polyurea concrete fix product, which cures in about 15 minutes. Once the concrete fix is hardened, we regrind and vacuum all potential contaminants.
2. POLYUREA BASECOAT APPLICATION
Once the concrete is ready for coating, we prepare all of our supplies, tools and buckets of flake for rapid installation. Our product cure rate is the boss, so we work with respect to the time. After the base coat is mixed, it only has 10-15 minutes to be applied to the ground before it will begin to cure and harden. With the understanding of our workflow, we will be able to communicate effectively so we can prepare to broadcast flakes as we are coating the floor. The base coat is applied over a wide area in small batches to ensure maximum coverage without losing or wasting any of the product. Once the first batch of the product has been applied, another small batch is made up and applied until the full floor is covered. Once the final batch has been mixed and poured onto the floor for dispersement, broadcasting of the flakes begins immediately over the covered area.
3. BROADCASTING FLAKES
As the final batch of base coat is being spread out over the floor, the prepared buckets of colored flakes will be administered by the handful over the floor. The base coat bonds with every flake that it touches, so because of this, we throw flakes to rejection - meaning, the point at which the base coat is fully covered with loose flakes so that it could not possibly receive any more. After every inch of the base coat has been covered with a thick layer of loose flakes, the flakes are left to bond for one hour.
4. SCRAPING FLAKES
After the flakes have set for at least an hour and the base coat has made its bond, we run a scraper from every direction along every inch of the floor to remove loose flakes and to flatten out jagged flakes. In doing this, we give the floor a semi-textured feel that is not harsh to walk on with bare feet. After this, we clean up the flakes and vacuum every inch of the floor to ensure that no loose flakes or potential contaminants are present for top coat application.
5. POLYASPARTIC TOP COAT APPLICATION
At this point, we will mix up a batch of the top coat and apply generously to the floor. We apply to the edges first and then fill in the middle of the floor. Once the whole floor is covered, we use our paint roller to backroll over every inch of the floor to make sure that there is full, uniform coverage.
6. ALLOW TO CURE
When we finish applying the top coat, the install has been finished and the curing process - the longest part of this process - begins. It is very important to not step onto the floor for a minimum of 8 hours to allow the top coat to bond completely to the polyurea and flakes on a molecular level. After 24 full hours, the floor will be totally cured.