Product #1 – High-Build Epoxy Floor Coating
Installation Guide

Product #1 All-Purpose High Build Epoxy Floor Coating is a two-component, 100% solids, zero VOC epoxy designed for high foot traffic and light to moderate forklift traffic areas. It is used for abrasion-resistant floors, light chemical exposure, and as a decorative waterproof coating for walls, floors, tanks, and similar surfaces.

This guide walks you through the general installation steps for Product #1. Always read and follow the current Technical Data Sheet (TDS) and Safety Data Sheet (SDS) for complete details, limits, and safety information.

1. Read This First – Surface Prep Comes Before Coating

No epoxy coating is better than the surface it’s bonded to. Before you think about mixing Product #1, make sure the substrate has been prepared properly.

For detailed instructions, see theEpoxy Surfae Preparation. Guideon this site. In summary, the surface should be:

Structurally sound – no loose, weak, or crumbling concrete.
Clean – free of oil, grease, curing compounds, sealers, paint, and other contaminants.
Mechanically profiled – shotblasted or ground to a suitable concrete surface profile (CSP).
Dry and within acceptable moisture/vapor limits for the system.

Do not skip surface preparation. Most failures blamed on “bad epoxy” are actually surface prep problems.

2. Job Supplies and Tools

The exact tools may vary by job, but a typical Product #1 installation will require:

Protective gloves, safety glasses, and appropriate personal protective equipment (PPE).
Clean mixing pails and calibrated measuring containers (if not using pre-proportioned kits).
Low-speed drill with mixing paddle suitable for epoxy.
3/8" or 1/2" shed-resistant rollers on sturdy frames with extension poles.
Spike shoes (if used) for walking on wet material during installation.
Masking materials for edges, drains, and transitions.
Industrial vacuum and/or blower for final dust removal before priming and coating.

Review the project-specific TDS for recommended coverage rates so you can calculate the total material required.

3. Priming

Many Product #1 systems perform best over a suitable primer, especially on porous or marginal concrete. The choice of primer depends on substrate condition and service requirements.

General guidelines:

Use the primer recommended in the Product #1 system specification or by Technical Support.
Apply primer to properly prepared concrete at the coverage rate specified in the primer’s TDS.
Allow the primer to cure within its recommended recoat window before applying Product #1.

Do not apply Product #1 over contaminated, glossy, or out-of-window primer without proper re-preparation.

4. Mixing Product #1

Product #1 is a two-component epoxy system consisting of Part A (resin) and Part B (hardener). Accurate proportioning and thorough mixing are essential for proper cure and performance.

Basic mixing procedure:

Pre-condition materials to the recommended application temperature range. Extremely hot or cold material will affect working time and viscosity.
Examine Part A and Part B to ensure there is no settling or separation that requires pre-stirring. If needed, stir each component individually before combining.
Add the full amount of Part B into the measured quantity of Part A as specified on the Product #1 TDS. Do not guess at ratios; follow the written instructions exactly.
Mix with a low-speed drill and paddle, scraping the sides and bottom of the pail as you go. Mix until the blend is uniform and streak-free, typically several minutes depending on batch size.
Avoid whipping air into the mix. Keep the paddle below the surface of the liquid while mixing.

Do not leave mixed material in a deep mass longer than necessary. Transfer to application pails or onto the floor promptly to maximize working time.

5. Application – High-Build Floor Coating

Immediately after mixing, pour a ribbon of Product #1 onto the floor in a manageable section. Do not try to coat too large an area at once — epoxy rewards steady progress, not rushing.

Dip-and-roll is the easiest and most reliable method for installing Product #1, and is recommended for most projects. Simply dip the roller into the mixed material and apply directly to the floor, working in small, controlled sections. This method keeps the material moving, maintains film thickness, and reduces the chance of cold joints.

If you prefer the spread-and-back-roll method:

Use a notched squeegee or trowel to distribute the coating to the target film thickness.
Work in a consistent pattern to maintain even coverage.
Back-roll immediately with a suitable roller to level the coating and remove squeegee lines.
Roll in two directions (90° to each other) for the best finish.

Whichever method you choose, maintain a wet edge as you move across the floor. Blend new mixes into the previous section while it is still workable to avoid visible lap lines or cold joints.

If you need to walk on the wet material during installation, use spike shoes. Take care not to track dust or debris into the coating — clean movement makes clean floors.

Product #1 is typically installed as a high-build coating in the range specified on the TDS (for example, 21–27 mils, including primer thickness). The exact thickness depends on the system design and service conditions.

General application steps:

Edges, terminations, and tight areas can be cut in with a brush or smaller roller before or during main application.

6. Second Coat or Topcoat

Product #1 systems are typically installed as a two-coat high-build system. Single-coat applications are discouraged. A second coat increases durability, improves coverage uniformity, and provides a better long-term surface. Adding a slip-resistant material such as Epoxy.com Synthetic Anti-Skid is optional but recommended anywhere improved traction is desired.

Allow the first coat to cure within the recoat window listed on the Product #1 TDS.
If the first coat goes beyond its recoat window or becomes glossy or contaminated, lightly abrade and clean it before recoating.
Apply the second coat using the same mixing and application procedures as the first.

If additional texture or slip resistance is specified, broadcast the approved aggregate into the wet coating or apply a textured topcoat as defined in the system design.

7. Curing and Return to Service

Cure time for Product #1 depends on temperature, film thickness, and ventilation. Refer to the Product #1 TDS for specific cure schedules.

General guidelines:

Protect the floor from dust, debris, and traffic during the full cure period.
Light foot traffic is usually allowed after the initial cure time listed on the TDS.
Heavy traffic, forklift use, and chemical exposure should wait until full cure is reached.

Do not wash or expose the new coating to aggressive chemicals until it has fully cured.

8. Safety and Handling

Always read and follow the Safety Data Sheets (SDS) for both Part A and Part B before use. Basic precautions include:

Wear appropriate gloves, eye protection, and clothing.
Provide adequate ventilation in enclosed areas.
Avoid skin and eye contact; wash thoroughly after handling.
Store materials in original containers and keep them tightly closed when not in use.
Dispose of mixed and unmixed material in accordance with local regulations.

If you are unsure about any aspect of safe handling or disposal, contact Technical Support for guidance.

9. Troubleshooting – Common Issues

Peeling or poor adhesion: Usually related to inadequate surface preparation, contaminants, or moisture/vapor issues.
Soft or tacky areas: Often caused by improper mix ratio, incomplete mixing, or contamination during cure.
Roller marks or uneven gloss: Can result from uneven film thickness, working too far out of the wet edge, or applying outside the recommended temperature range.

When in doubt, stop and call Technical Support before proceeding. Early advice is almost always cheaper than repair.

Product #1 – High-Build Epoxy Floor CoatingInstallation Guide