Epoxy Flooring Installation

What is an epoxy floor coating, and where does it fit best?

An epoxy floor coating is a resin layer that bonds to concrete and cures into a hard, glossy, seam-free surface. It works best on floors that take chemicals, forklifts or constant cleaning. AES installs it in plants, warehouses, labs and garages across the St. Louis area.

AES describes its epoxy as high gloss, hard wearing, chemically resistant and self-leveling. Because the cured surface is nonporous and has no seams, it does not trap dirt. That is why food, beverage and pharmaceutical plants use it.

Space	Why epoxy fits	What to ask
Manufacturing and industrial plants	Chemical resistance, wear resistance	Which chemicals touch the floor
Food and beverage plants	Nonporous, seam-free, wipes clean	Wash-down and drain needs
Pharmaceutical buildings and labs	Easy to clean, no seams to trap dirt	Dust control during install
Warehouses and shipping	Less wear from transport vehicles, bright surface	Forklift loads
Water and wastewater plants	Chemical resistance	Exposure type
Garages	Gloss, durable, easy to wipe	Hot tire pickup, moisture

AES lists these uses: commercial facilities, industrial plants, food and beverage plants, pharmaceutical manufacturing buildings, water and wastewater treatment plants, laboratories, storage and shipping warehouses, and architectural applications. Its brochure also names airplane hangars, chemical plants, distribution facilities and residential garages. See the glossary entry on epoxy floor coating.

What systems does AES install?

AES’s floor division lists epoxy floor coating, chip systems, PVC flooring, shot blasting, moisture barriers, diamond grinding, underlayment pumping, concrete polishing and staining, and flooring and adhesive removal. This list comes from the AES brochure. Epoxy is the core product, and the others prepare or support it.

The main epoxy product AES links to is Perma-Tuff SL, a self-leveling epoxy made by Induron Protective Coatings. The pamphlet describes it as a two-component, 100% solids, high performance epoxy for properly prepared concrete floors. It says film thickness can be varied to suit different floor conditions. AES’s page says the same about varied film thickness, which is why one product can serve many jobs.

Here is how the pieces fit:

• Epoxy floor coating. The main system for gloss, chemical resistance and a seam-free surface.
• Chip systems. Listed in the brochure. Ask AES how a chip system fits your space.
• PVC flooring. AES’s brochure lists it as an option for commercial kitchens, clinics and bathrooms. It says seams are welded and can be coved to meet health codes.
• Underlayment pumping. The brochure says it can transform non-repairable concrete for forklift traffic in as little as 16 hours.
• Moisture barriers. A liquid layer under flooring that cuts vapor transmission.
• Shot blasting and diamond grinding. Prep methods that open the slab so coatings bond.

AES says its installation team has been factory trained and certified by the manufacturers, which assures product warranty. You can read the epoxy flooring brochure yourself.

Why does surface prep decide how long an epoxy floor lasts?

Epoxy only lasts as long as its bond to the slab. Dirt, oil, old coatings, glue and weak concrete break that bond. Prep removes them and opens the surface so the coating grips. For that reason, grinding or shot blasting is the first step on an AES epoxy job.

AES uses two prep methods. Shot blasting strips the surface mechanically. Concrete grinding uses diamond-disc machines with dust suppression systems. AES says dust control is essential in medical and pharmaceutical settings. See concrete grinding contractors for more.

A basic prep checklist:

1. Remove old flooring, adhesive and coatings. See floor adhesive removal.
2. Test old tile and glue for asbestos before disturbing them. AES says it is equipped to remove asbestos and lead containing materials before new flooring goes in.
3. Grind or shot blast to open the slab.
4. Repair cracks and low spots.
5. Test for moisture.
6. Clean and vacuum.
7. Apply primer if the system calls for one, then the epoxy.

Skipping any step puts the coating at risk. The concrete floor prep guide explains each step in more detail.

When does a slab need a moisture barrier?

A slab needs a moisture barrier when it passes too much water vapor for the coating or flooring on top. Test the slab to find out. AES offers calcium chloride testing and relative humidity testing to measure the vapor transmission rate, known as MVER, and decides from the results.

Moisture is the hidden reason many coatings fail. Vapor rising through concrete can push against a coating until it lifts or bubbles. A barrier stops that. The moisture barrier glossary entry gives a short definition.

AES applies two-component, seam-free liquid epoxy barriers over concrete and under the finished floor. The moisture barriers page and the brochure list these features:

• Ability to treat concrete at 25 lb. MVER and 100% humidity
• Vapor transmission reduced to near zero
• Zero VOC rating, which contributes to LEED / GREEN building
• Compatibility with most floor covering surfaces
• Application over dry or damp surfaces, even 5-day old concrete
• An available 10 year guarantee

Word that last point carefully. The 10 year guarantee is a feature the brochure lists for the liquid barrier product. It is not a blanket promise for every AES floor. Ask for the guarantee terms in writing: what it covers, who backs it and what slab conditions apply.

Question	Why it matters
What are the MVER and humidity readings?	They show whether a barrier is needed
Is the concrete new?	Fast-track jobs often cannot wait for full cure
What goes on top?	Tile, vinyl, carpet, wood and epoxy react differently
Is there cooler or wet-area use?	AES lists coolers and wet weather among barrier uses

Epoxy or polished concrete: which fits my space?

Choose epoxy for chemical resistance, a seam-free nonporous surface and marked safety zones. Choose polished concrete for a natural look, simple care and a surface that comes from the slab itself. Both begin with grinding, and AES installs both.

Factor	Epoxy floor coating	Polished concrete
How it works	A coating bonds on top of the slab	The slab itself is ground and polished
Chemical resistance	High, per AES	Improves with a sealer
Seams	None, per AES	None, but joints in the slab remain
Look	High gloss, solid colors and safety zones	Stone-like, can be stained
Maintenance	Wipe or mop	Damp cloth or mop, per AES
Refinish	Recoat when worn	AES says heavy-traffic floors may need refinishing every 5 to 10 years
Moisture risk	Needs a slab test	Less coating to lift, but still check

AES says epoxy improves safety. It is impact, slip and fire resistant, and it improves brightness by 300% and outlines safety zones. It also says epoxy can raise productivity by reducing wear on transport vehicles and speeding material movement. These are AES’s own statements about its product.

For a deeper side-by-side, read polished concrete vs epoxy and the concrete polishing page. If you want color on polished concrete, see concrete staining.

How long does installation take, and when can the floor be used?

AES does not publish one install time for epoxy. The schedule depends on slab condition, prep needs, moisture, the number of coats and the product’s cure time. Ask for a day-by-day plan, including when foot traffic, then forklift traffic, is safe.

AES says its epoxy has a quick and easy application process and that it is self-leveling, which makes it quick and easy to install over new or old concrete. The brochure says underlayment pumping can ready non-repairable concrete for forklift traffic in as little as 16 hours. That figure applies to underlayment, not to the epoxy coat.

When you request a quote, ask:

• How many days will the floor be closed?
• When can people walk on it? When can vehicles drive on it?
• Can the job run in phases to keep part of the building open?
• What temperature and humidity does the product need?

Garage, warehouse, healthcare, food plant: what changes?

The system, the prep and the paperwork change with the space. A garage needs a tough, easy-clean finish. A warehouse needs wear resistance and visible lanes. A healthcare or food space needs a seam-free, nonporous surface and dust control. A plant may need chemical resistance first.

Space	What changes
Garage	Residential garages are on AES’s brochure list. Check for moisture and old sealers.
Warehouse and shipping	Safety zones and lane markings help, and AES says epoxy reduces wear on transport vehicles.
Healthcare and pharmaceutical	Seam-free, nonporous floors do not trap dirt, and dust suppression during grinding is essential. See healthcare environmental services.
Food and beverage	AES notes the nonporous, seam-free surface suits food preparation and packaging plants. Ask about wash-down and coving.
Chemical or industrial plant	AES calls its epoxy chemically resistant. Name the chemicals so the system is matched.

Older buildings add one more step. Floors from older eras may have asbestos-containing tile or adhesive. AES can test and remove it under the rules before it coats the slab. See asbestos floor tile and asbestos testing. The gallery shows epoxy flooring and concrete finishing projects.

Next step

Tell AES about the space, the slab and the use. Call (314) 865-2662 or request a free quote on the contact page. Ask for slab moisture testing, a written prep plan and the terms of any guarantee.