Surface Coating Processs
The Rexyco Floor
The Rexyco Floor
The Rexyco Floor
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Our system is a hybrid: Epoxy Moisture Vapor Barrier base and Polyaspartic topcoat. Epoxy is thick, it creates a strong chemical bond with the cement. Polyaspartic resin is UV stable (epoxy will yellow over time) and has greater scratch resistance than epoxy. The following gives a general idea of the Flake or Quartz coating process.
1. Protection
The Rexyco Floor
The Rexyco Floor
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Cover driveway with boards to protect surrounding surfaces.
Protect garage walls and other areas with plastic and/or tape.
2. Concrete Prep
The Rexyco Floor
3. Base Coat/ Moisture Vapor Barrier Coat
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Machine grind concrete with a diamond grinder, manual grinding of floor edging.
Patch cracks, spalling, etc. Large cracks to be ground down using diamond blade and filled with a urethane crack repair.
Dustcontrol TROMB, OSHA regulated HEPA vacuum systems used while grinding.
3. Base Coat/ Moisture Vapor Barrier Coat
3. Base Coat/ Moisture Vapor Barrier Coat
3. Base Coat/ Moisture Vapor Barrier Coat
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Apply a pigmented Epoxy Moisture Vapor Barrier(MVB)to prevent ground water from affecting slab.
4. Broadcast Coat
3. Base Coat/ Moisture Vapor Barrier Coat
4. Broadcast Coat
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Broadcast Customer Chosen Chips/flakes or Quartz into the MVB. Allow MVB to dry.
5. Top Coat
3. Base Coat/ Moisture Vapor Barrier Coat
4. Broadcast Coat
Apply one to two top coats of clear Polyaspartic with optional traction additive for extra slip resistance.
Need more info?
Here is a deeper look at the floor coating process:
DIAMOND GRIND THE SURFACE- industrial HEPA filtered vacuums minimize dust
Preparation of the concrete prior to applying the base coat layer is critical and essential to the durability and longevity of the epoxy floor coating system. Rexyco uses mechanical grinders with diamond tooling. This is more effective than the acid wash method recommended by the DIY systems currently on the market. Diamond grinding scrapes the surface of the concrete to open up the pores as well as eliminate surface contaminants, like paint, motor oil and other lubricants.
PATCHING OF CRACKS, CHIPS & PITTING
Our prep work also includes patching any areas with Urethane Crack Repair. The urethane sets in approximately 20 minutes. Once dry, a second grinding of the floor is completed in the opposite direction of the first pass. Multidirectional grinding ensures maximum adherence of the base coat. Floors that require extensive repair may require additional time.
MOSTIURE VAPOR BARRIER (MVB)- BASE COAT
This step sets us apart from our competition. We use MVB on every floor. Why? Because we work in Upstate New York. We apply a thick layer of industrial grade, 100% solid, MOSTURE VAPOR BARRIER epoxy. This epoxy is designed to absorb deep into the pores of the concrete surface. MVB is available in slow and fast cure options. Fast and slow cure MVB are equally deep penetrating and promote superior adhesion AND PROTECTION AGAINST GROUND WATER.
DECORATIVE FLAKES/CHIPS
The decorative polymer chips are then broadcasted into the wet MVB epoxy and chemically bond together—which ultimately gives the coating the look of Granite or Terrazzo. The flakes also add body to the epoxy, increasing the overall strength of the system as well as create a texture which increases the overall slip resistance of the system. In order to achieve 100% coverage, we will apply an additional 20-30% more flakes.
MVB DRY TIME
MVB Dry time is based on the product customer selects. This can range from 2 hours to 24 or more. Heat and humidity greatly affect dry time, so each floor will vary. If the floor requires to cure overnight, doors are left ajar as shown, with plastic sheeting for protection. Once the floor is dry we remove the excess flake material using a flat metal edged tool to knock down any standing flakes. The entire floor is then blown off and vacuumed to remove any excess debris.
POLYASPARTIC TOP COAT
Now the floor is even and smooth, it is ready for the final step. The application of a durable, high quality, UV stable, scratch, chemical and stain resistant polyaspartic top coat. The top coat requires 24 hours* to cure for foot traffic and 48 hours for vehicles. Once completed, you will have an attractive, high quality and extremely durable floor.
* times may vary