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How to apply commercial kitchen epoxy flooring

The following guide includes hints, tips and instructions for installing the high-build, non-slip epoxy flooring system
manufactured by Real World Epoxies - Resin Rock™


1. Surface preparation

Contaminated concrete:

To determine if the concrete is contaminated with oil or grease, drip a small amount of water onto the surface. If the water beads, the concrete should be before any other surface preparation is performed.

Painted or sealed concrete:

Previous paints or sealers should be removed with a diamond grinder prior to application.

Moisture in concrete:

Inspect surface for signs of dampness or efflorescence. If there are no visible signs, test with a moisture meter. If the moisture content exceeds 5.5% or there’s a relative humidity of 70% or greater, apply a moisture barrier.

Loose concrete and dust:

Ensure all loose material is removed from the surface and damaged areas are repaired prior to application.

Flatness:

For best results, the substrate should not deviate more than the following distances under a straight edge tool:

  • 3mm over 3m (flatness),
  • 1mm over 150mm (smoothness),
  • 0.5mm over 50mm (projections).

If required, the substrate should be levelled first with a suitable levelling compound.

Cracks:

Fill static cracks, divots and gauges with a suitable patching compound, e.g. Ezypoxy Clear with Ezypatch filler. Dynamic cracks should be filled first before cutting out to form a control joint. The joint should be sealed with a suitable flexible joint sealant after application of the flooring system.

New concrete:

Allow concrete to harden for 28 days before conducting surface preparation as per the instructions below.

Preparation instructions:

Diamond grind to obtain a clean, granular/rough feel with a CSP 2-3 profile. Use a Schmidt hammer to test hardness of concrete so that the right disc segments can be chosen (e.g. hard or soft bond).

Properly prepared surfaces should be structurally sound and free of contamination, laitance and any loose material. Ensure prepared surface is clean, dry and dust-free again if there’s a delay between preparation and application.

Porous surfaces:

If the concrete is found to be particularly weak, powdery or porous during substrate preparation, apply a suitable primer/sealer, e.g. Ezypoxy Clear, to prevent the first coat from soaking in too much.

2. Setting up

Read these instructions in full before getting started.

Get all tools and the mix area ready before mixing. The mix area shouldn’t be too far away, cordoned off if possible and with product laid out neatly (in a cool place, away from direct sunlight). Make sure it’s big enough to allow plenty of room to move and work cleanly.

Use drop sheets to protect all surfaces from splashes/spills/drips, and have plenty of lint-free cotton rags and solvent for clean-up. It should also contain a separate clean area and a waste bin for discarded items.

3. Plan first coat - Resin Rock Slurry

Each batch - Ezypoxy Clear, RWE Slurry Mix and Solid-colour Pigment Pot - will cover approximately 10m2 @ 2000 microns/2mm (0.5m2/L).

Plan progress across the area. Consider how to finish kits, using joints as boundaries and keeping edges fresh so the next kit can be seamlessly worked in. Large joints should never be covered because cracks can appear. Apply up to the edge and let it run into the joint instead of trying to fill or cover completely. Flexible sealants can be used if desired after application is complete.

Mark out sections of the floor with masking tape as a guide to help you use the correct amount and achieve correct film thicknesses. Use this time to mask up any surfaces you wish to protect from accidental contact with the resin, e.g. skirting boards, drains, transition strips etc.

4. Mix Resin Rock Slurry

WARNING: Part B is a Class 8 Corrosive. For full safety instructions, consult SDS. Wear protective clothing, goggles and gloves to prevent skin and eye contact. Clean up can be made using methylated spirits or acetone.

Due to high viscosity of mix, use a geared mixer to blend components. Pre-mix filler and pigment pot into Part A first. For best results, let product sit for 30 minutes to allow resin to wet out.

Pour Part B into Part A and mix for 2 minutes or until a consistent colour is obtained, scraping sides to ensure all product is taken in.

Mixing notes:

  • In cooler conditions it may be necessary to mix Part A and Part B first before adding the filler and pigment.
  • Make sure aggregate is mixed well as lumps can appear in poorly mixed product.
  • Do not leave container in direct sunlight as heat will accelerate hardening reaction.
  • If more than one kit is mixed at a time, the hardening reaction can generate high temperatures and significantly reduce the pot life.

5. Apply Resin Rock Slurry

Start in the far corner, progressing across the room and back towards the point of exit.

Pour mixed topping onto the floor and position with the edge of the trowel.

Use the face to break up the pour lines and flatten the floor out. Keep the trowel in motion while applying using a fan-like pattern, i.e. start and finish “on the dry”.

Each kit must be applied within the pot life times listed in the Cure Schedule table to ensure best results.

Table - Ezypoxy Clear Cure Schedule

Temperature

Pot Life

Re-coat

Light Traffic

15oC

40 min.

36-48 hours

48 hours after final coat

25oC

20 min.

18-24 hours

24 hours after final coat

35oC

10 min.

9-12 hours

24 hours after final coat


Application tips:

  • Do not apply in temperatures lower than 5oC.
  • Do not add solvents as it can affect performance and lead to film defects such as soft spots.
  • To cut in, pour a thin bead of slurry approximately 5-10cm from the edge and use the trowel to spread it evenly into place.
  • The 250-micron film creates a rippled texture and semi-gloss finish.
  • Cut in with a brush or small trowel. Pour a thin bead of resin approximately 5-10cm from the edge and use the brush to spread it evenly into place.
  • The listed coverage is the maximum for one batch of Resin Rock Slurry. Batches can be split and used across smaller areas by using the following to make 1 litre:

  • Part A Part B
    1490g/800mL 200g/200mL


6. Broadcast Resin Grip HD

Broadcast the Resin Grip HD immediately after basecoat application. Wear spiked shoes to walk around on the freshly laid basecoat without leaving prints.

A technique similar to “chicken feeding” is most effective when broadcasting. Grab a “knuckle full” of aggregate and slowly sprinkle over the top.

A full saturation of the basecoat typically requires 3-4kg/m2 and the film should look “dry” (no glossy sections from the basecoat visible).

7. Collect excess aggregate/particle

Once the first coat is hard enough, carefully walk back on the floor and sweep off any loose particles. Clean aggregate can be re-used in the future if desired.

8. Plan second coat - Ezypoxy Rollcoat

Each kit of Ezypoxy Rollcoat will cover approximately 48m2 @ 250 microns (4m2/L).

Plan application as per first coat.

9. Mix Ezypoxy Rollcoat

WARNING: Part B is a Class 8 Corrosive. For full safety instructions, consult SDS. Wear protective clothing, goggles and gloves to prevent skin and eye contact. Clean up can be made using methylated spirits or acetone.

Pre-mix pigment pot into Part A first with a drill using a Jiffy mix blade. Pour Part B into Part A and mix for 2 minutes or until a consistent colour is obtained, scraping sides to ensure all product is taken in.

Mixing notes:

  • Unused Part A can have a solid-looking gel consistency that only starts to flow once mixed.
  • Do not leave container in direct sunlight as heat will accelerate hardening reaction.
  • To help mixing process in cool temperature (below 10oC), warm the components separately in hot water to 25oC beforehand. Over-heating the product will result in a significant reduction in pot life.
  • If more than one kit is mixed at a time, the hardening reaction can generate high temperatures and significantly reduce the pot life.

10. Apply Ezypoxy Rollcoat

The fully saturated layer of aggregate and coarse non-slip profile means a roller tray should be used to evenly apply the topcoat rather than squeegee and backroll.

The extra surface area created by the texture may require vigorous rolling to fully coat all the particles. Thicker films than the minimum 250 microns can be applied, but will result in a less aggressive non-slip profile.

When using a tray, take note of the cure schedule and only mix volumes that can be applied within the pot life period. Mixing full kits can lead to hardening before use.

Leave enough to cut in around tight areas with a brush. Try not to cut in too far, just enough to protect the vertical surfaces.

It’s a good idea to de-lint all rollers first by wrapping the roller in masking tape and removing. Repeat this process, fluffing the roller in between until there are no fibres visible on the back of the tape.

When rolling, use 12mm roller covers and aim for long, even, overlapping strokes to get the product feeling and sounding the same. The film will often make a soft tearing sound when rolled evenly. For best results, roll the film perpendicular to the first direction to finish.

Try to minimise the number of seams and keep them as fresh as possible. If left for too long, pigments can settle and lead to a visible colour difference.

Each kit must be applied within the pot life times listed in the Cure Schedule table to ensure best results.

Table - Ezypoxy Rollcoat Cure Schedule

Temperature

Pot Life

Re-coat

Light Traffic

15oC

40 min.

36-48 hours

48 hours after final coat

25oC

20 min.

18-24 hours

24 hours after final coat

35oC

10 min.

9-12 hours

24 hours after final coat


Application tips:

  • Do not apply in temperatures lower than 5oC.
  • The listed coverage is the maximum for one Ezypoxy Rollcoat kit. Kits can be split and used across smaller areas by using the following weights and volumes to make 1 litre:
Part A Part B
880g/660mL 350g/340mL


Once completed, the floor will be ready for light traffic in 24 hours and reach full hardness over 7 days.

11. Storage

Keep containers closed when not in use. Store below 40°C. Do not store in direct sunlight. Shelf life is at least 12 months in original, unopened container. Seek advice from your local council regarding accepted disposal methods.

12. First Aid

CAUTION: KEEP OUT OF REACH OF CHILDREN.  IF ON SKIN: Remove immediately all contaminated clothing. Rinse skin with water. IF IN EYES: Rinse cautiously with water for several minutes. Immediately call a POISON CENTRE (Australia - 13 11 26) or doctor/physician. If skin irritation occurs: Get medical advice/attention. 


Our technical advice, whether verbal or in writing, is given in good faith but without warranty. This also applies where proprietary rights of third parties are involved. It does not release the user from the obligation to test the products supplied for their suitability in the intended processes and uses.


Download a copy of the installation guide - Resin Rock™ 

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