Epoxy Flooring Checklist in Fairfax, VA

Specification and paperwork

• Written specification naming the system, the resin chemistry and the total dry film thickness (20–35 mils, not 2–5)A verbal scope cannot be inspected later.
• Layer stack documented: primer, base coat, broadcasts, topcoat
• Moisture testing scheduled before the install date, not on the day
• Return-to-service dates agreed in writing for the space being coated

Slab prerequisites

• Concrete is at least 28 days past the pour
• Compressive strength is 2,500 PSI or higher
• Moisture emission tested to ASTM F1869 — at or under 5 lb per 1,000 sq ft per 24 hoursAbove that, specify a moisture vapour barrier primer.
• Internal relative humidity tested to ASTM F2170 — at or under 75%Above 75% RH, specify a moisture vapour barrier primer.
• No curing compounds, sealers, paint or adhesive residue left on the surface
• Oil, grease and coolant spots stripped back to bare concrete

Mechanical preparation

• Diamond grinding or shot blasting performed to reach ICRI CSP 3–4
• Edges, corners and tight spaces ground by hand for uniform adhesion
• Moving cracks and joints routed out and filled with a flexible epoxy
• HEPA dust extraction used throughoutSilica dust control is an OSHA requirement, not an option.
• Floor vacuumed and verified dry before the primer goes down

Conditions and sign-off

• Slab temperature and ambient conditions inside the product data sheet window
• Ventilation arranged for the work area
• CSP 3–4 profile verified and photographed
• Moisture readings recorded and filed with the project paperwork
• Before photos taken of every area to be coated

Materials on site

• Correct products delivered, unopened and within date
• Batch numbers photographed and logged for every pail
• Aggregate quantity confirmed for the coverage rate (about 160 sq ft per 100 lb first broadcast, 200 sq ft per 100 lb second)
• Mixing ratios and pot life read off the data sheet before mixing starts

Conditions before mixing

• Slab temperature, air temperature and humidity recorded
• Dew point checked — slab must be above it to avoid amine blush
• Ventilation running; work area protected from traffic, pets and dust

Application sequence

• Primer applied at 250–300 sq ft per gallon and left to penetrate
• Base coat applied at 125–150 sq ft per gallon
• First aggregate broadcast into the wet base coat
• Binder or second coat at 75–100 sq ft per gallon with the second broadcast
• Pigmented topcoat at 100–150 sq ft per gallon
• Edges and corners cut in with every layer, not just the first
• Broadcast material fully back-rolled or sealed so no loose grit remains

Safety and site control

• Chemical splash goggles, impermeable gloves, apron and protective boots worn
• Supplied-air or appropriate respirator used for aerosol risks
• Spill wash water contained — never flushed to storm drains
• Barriers and signage up; no access until the cure gates are met

Cure gates respected

• No pedestrian traffic for the first 48 hours
• No vehicles, jacks or forklifts before 72 hours (rapid-cure polyaspartic systems: about 24 hours)
• Full cure at five days before heavy abrasion or chemical exposure
• Space kept clean and dust-free throughout the cure

Visual inspection

• No bubbles, blisters or outgassing craters anywhere on the field
• No delamination or lifting at edges, thresholds or penetrations
• Colour and aggregate distribution uniform across the floor
• No pinholes, fish-eyes or debris sealed into the film
• Existing expansion joints still free to move

Safety and performance verification

• Anti-slip texture present on walkways, slopes and work zones
• Lighting good enough to see the finish clearly at night
• Vehicles and heavy items placed only after the cure gate passed

Handover and warranty

• Project-specific warranty registered and the certificate sent to the owner
• Maintenance instructions handed over in writing
• Touch-up material left on site with the batch reference
• Specification sheet, moisture readings and photos filed
• Final walkthrough signed off by both parties

Weekly

• Sweep or dust-mop the full floor to remove gritGrit under tyres and boots is what dulls a gloss finish first.
• Damp mop with a pH-neutral cleaner; no abrasive pads on a gloss topcoat
• Wipe oil, antifreeze, fuel and brine spills when they happen, not at the weekend

Seasonal

• Rinse winter salt and brine residue before it sits
• Let tyres cool before parking on the same spot; use mats where heavy vehicles park hot
• Check the floor after the first freeze cycle for new cracking at joints

Annual

• Inspect for dulling, scratches and worn traffic lanes
• Inspect expansion joints and re-fill if the flexible epoxy has moved
• Refresh a clear topcoat when the shine fades — rejuvenation costs far less than a tear-out
• Re-check moisture-prone walls and thresholds for efflorescence

Never

• Solvent strippers such as methylene chloride — they remove resin floors
• Concentrated acids left standing on the surface; clean immediately
• Steel wool, scouring pads or aggressive brushes on the finish
• Dragging metal objects, engine blocks or bare tool boxes across the floor

If more than a couple of boxes are unticked

That is the point of the list. A missing moisture test, an acid etch instead of a mechanical profile, or traffic allowed on the floor before the cure gate has passed are the three reasons coated floors fail early in this climate — and all three are decisions made before and during the install, not after. Bring the unticked items to your contractor as questions.