How to Install a Polyurea Concrete Coating

Introduction: Commence with Training

Before initiating any flooring installation, it is imperative to educate your team. Adopting a consistent training regimen is crucial as it guarantees precision in execution by your installers, ensuring optimal outcomes every time. Whenever feasible, receiving training directly from the manufacturer at their site is advantageous. This allows your team to engage directly with experts, addressing specific product queries and gaining practical experience.

Step 1: Surface Preparation

The success of the flooring installation largely depends on how well the concrete surface is prepared. It is essential to eliminate any laitance, sealers, and pollutants that could hinder the coating’s ability to bond with the concrete. The choice of preparation technique should suit the specific needs of the project. Typically, this involves mechanically profiling the surface—via methods such as shot blasting, diamond grinding, or scarifying—to expose and open up the concrete’s pores.

Step 2: Mend Cracks and Joints

After the surface is thoroughly prepared, attention should be turned to fixing any cracks and joints. It is advisable to use a polyurea-based compound for its excellent flexibility and quick setting properties. Enhancements like sand or pea gravel may be incorporated into the repair mixture to increase its volume and help fill larger cavities, such as spalls and cracks. For contraction joints, it is recommended not to fill them completely. Instead, applying coating into and then out of the joints is preferred to prevent potential cracking in other areas of the slab.

Step 3: Primer Application

Apply the primer according to the manufacturer’s recommended number of coats and thickness. Primers can be either transparent, like Clear Eco-Prime, or pigmented, such as Polyurea 350 with Color Tint. Depending on the type of flooring system being installed, a primer might not always be necessary. For instance, some systems use a product that functions as both a primer and a base coat. Alternatively, a simple application of a tinted primer followed by a clear coat might suffice, which allows you to bypass additional steps and proceed directly to the final layer.

Step 4: Apply the Bed Layer

The primer should be allowed to cure for 2 to 4 hours, depending on ambient temperature conditions, to a stage where it is walkable. Following this, the second layer is applied. This bed layer is crucial for systems that include multiple coatings, such as metallic, Medici, or chip-enhanced garage floor systems. For surfaces utilizing vinyl chips or quartz sand, these materials should be broadcast immediately into the wet bed layer. Using polyurea helps the chips to settle parallel to the floor, creating a uniform, laminar effect that enhances both the protection of the concrete and the durability of the finish.

Step 5: Top Coat Application

Once the bed layer has set, the surface should be rigorously scraped with a floor scraper to remove excess chips, smoothing the surface and minimizing the volume of top coat required. Any loose materials are then vacuumed away before the final coat is applied using a flat blade squeegee. Polyurea’s rapid curing properties allow the entire process to be completed swiftly, with the flooring ready for pedestrian traffic in just 4 to 6 hours and vehicle traffic within a day.

Conclusion: Expert Assistance Available

If you are new to this type of installation or have recently expanded your team, additional training may be beneficial. We encourage you to arrange a consultation with one of our experienced flooring specialists to enhance your team’s capabilities and ensure your next project is a success.

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