Surface Preparation Over Existing Resin Floors
Epoxy.com Technical Bulletin
1. General Information
Recoating can be an excellent way to restore appearance and performance when the existing epoxy floor is properly prepared and is still firmly bonded to the substrate. Many existing resin floors remain structurally sound even after years of service but may show wear, dullness, or abrasion in high-traffic areas. With correct preparation, these floors can be renewed by applying a compatible Epoxy.com coating system.
This bulletin outlines the correct procedure for cleaning, testing, repairing, and mechanically profiling a properly prepared existing epoxy floor prior to installing a new Epoxy.com system.
2. Cleaning the Existing Floor
A clean surface is essential before any further evaluation or preparation can occur. Remove loose dirt and debris, then scrub with a suitable detergent or degreaser. For oily or unknown contamination, we recommend contacting your trusted local janitorial supply house for the correct cleaner for your specific contaminants.
Rinse thoroughly and allow the floor to dry completely.
3. Verify Bond of Existing Epoxy (Installer Responsibility)
The installer must verify that the existing epoxy floor is firmly bonded to its substrate before recoating. This evaluation includes:
- Sounding the floor for hollow or loose areas
- Performing adhesion tests where appropriate
- Identifying blistered, delaminated, or weak spots
- Determining whether contamination has compromised the old bond
Only well-bonded, structurally sound areas are suitable for recoating.
Important Clarification
If the existing epoxy floor is not properly prepared or is not firmly bonded to the concrete substrate, nothing can prevent that old layer from releasing. If the old epoxy lifts, the new epoxy will lift with it — regardless of how strong the bond is between the new and old coating.
It is the installer’s responsibility to confirm that the existing floor is prepared correctly, sound, and well bonded before applying any new Epoxy.com materials.
4. Remove Loose or Weak Material
All loose, soft, delaminated, or deteriorated epoxy must be removed. Grind, scrape, or chip back to firm, well-adhered edges. Weak material left on the surface will undermine the new coating system.
5. Repairs Using Product #2704
After removing unsound material, repair all defects with:
Epoxy Gel – Product #2704 (Super Fast Cure)
#2704 is ideal for:
- Feathering transitions
- Patching divots or shallow spalls
- Filling small cracks or gouges
- Stabilizing edges where old epoxy was removed
Allow repairs to fully cure before mechanical profiling.
6. Mechanical Surface Profiling
Existing epoxy must be mechanically abraded to remove gloss and create profile. Accepted methods include:
- Floor buffer with 60–100 grit abrasive screens
- Diamond grinding equipment
- Carbide scrapers
- Carborundum stones
- Light shot blasting (if appropriate)
The goal is to produce a uniform, de-glossed surface with enough mechanical “tooth” to ensure proper adhesion. Chemical etching is not acceptable for existing resin floors.
7. Application Conditions
Before installing new epoxy:
- The surface must be clean, dry, and dust-free
- Environmental conditions must match the product requirements
- Repairs must be cured and sanded
- No condensation or moisture film may be present
8. Selecting the Correct Epoxy.com Recoat System
Recoating must be done with a compatible Epoxy.com system chosen for the intended service conditions.
Clear Recoat / Sealer
Pigmented Recoat Options
- Product #1– general-purpose high-build epoxy
- Product #2– chemical-resistant epoxy
- Product #633– high chemical and solvent resistance
If unsure which system is appropriate, contact Epoxy.com Technical Support.
9. Summary
- Clean thoroughly
- Installer must verify proper preparation and bond
- Remove loose or unsound material
- Patch withProduct #2704
- Mechanically de-gloss and profile
- Ensure proper environmental conditions
- Recoat with #15, #1, #2, or #633 depending on requirements