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Asking for opinions about prepping this floor

robmack

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Jul 16, 2010
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46
Location
Toronto, CANADA
Hi,

I've been reading posts in this Flooring forum for some weeks now. I am preparing to epoxy my two-car garage floor and have been scouring posts for information about repairing concrete. I'm looking for opinions about the strategy I should use to get this garage floor of mine ready for the epoxy.

The floor is the original one from 1963. The concrete has never been coated or treated in its lifetime and there is deterioration from winter salt and frost damage or ground shifting as a result. The pictures below shows the general condition of the concrete.

There is a large area of the floor with spalling damage I believe, as in the photos below:
116.JPG

115.JPG

120.JPG

There are several cracks as well. They appear to go through the floor but I am uncertain (photo of one below):
119.JPG

The concrete also appears to have huge pits, probably mechanicla damage from crumbling due to frost or ice. The photos below give a general indication of the size and depth of this damage:
114.JPG
113.JPG
.
The previous owner appears to have tried to patch the concrete but his/her handywork is very poor:
118.JPG

One large concern is that the previous owner built up the ledge at the garage door with some asphalt, which causes water damming inside the garage when it rains:
121.JPG


I have an idea that I will need to patch the pits and cracks in the concrete with a flexible concrete patching material. Then, I will need to grind the surface to even out the texture. Subsequently, I'll apply a bonding primer and finally the epoxy paint.

My concern is whether the plan above is comprehensive, sound and achievable. Also, I have no idea how to tackle the ledge of the garage door. Can this asphalt hump be easily removed? I have looked at installing a linear drain at the ledge to catch runoff.

Can others with greater experience and knowledge than I help me to come up with a plan to tackle this project. My budget is tight (who's isn't). I have received one quote from a professional firn who specializes in resurfacing concrete. They haven't seen the floor but said a ballpark figure of $7/sq.ft. would be a good planning number. This would not include applying the epoxy; just resurfacing. This figure is too high for my budget and I'd need to reduce it by half, and so I'd like to do most of the work myself if possible.

Thanks for any help.
 
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robmack

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Toronto, CANADA
I don't think I can use Racedeck. I have several woodworking machines in the garage. They are on mobile bases however the machines are very heavy (two are 200KG each). It is the machines that are driving the need for this floor repair / resurfacing in the first place. The point pressure they exert on each wheel on the mobile base would press into the Racedeck. It means that if the machines sit for any length of time, they may press into the Racedeck, making them very difficult to get moving and leaving behind deep dents in the flooring. I have the impression that epoxy is my only flooring coating choice (or acid etching or staining, but I think either of those needs professional application and a reasonably good floor with which to begin).

Thanks for the suggestion. I will do a complete investigation about RaceDeck before I rule it out; it looks very good and if it handles my machine loading, I will definitely use it.
 
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28HopUp

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Mar 16, 2010
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295
Location
Lowcountry SC
My concern is whether the plan above is comprehensive, sound and achievable. Also, I have no idea how to tackle the ledge of the garage door. Can this asphalt hump be easily removed? I have looked at installing a linear drain at the ledge to catch runoff.

You can use a circle-saw with a masonry blade to cut a clean line for removing the section of asphalt with the hump. Then you can insert your drain pipe and patch the section with new asphalt. Some professionals can remelt the surface for a practically invisible seam. A coat of driveway sealer also hides many sins.
 
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Rickster55

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Jun 22, 2009
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Location
Syracuse, NY
If I hadn't known better, I would have said the first, second and last picture looks like it was of my garage floor. I'll be following this thread for some answers too.
 

LegacyIndustrial

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deerfield, IL
Prefill the "spalled" areas with a self leveling epoxy or epoxy patch material.
Flat blade the material with a squeegee.
Then coat with a good 100% solids epoxy coating.
 
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kkaldor

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Jun 1, 2010
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Rob,

I just repaired my floor which looked very similar to yours minus the asphalt dam in front of the door. See this thread for my procedure http://www.garagejournal.com/forum/showthread.php?t=69631

I am also a woodworker and had to repair the floor to roll around my new cabinet style tablesaw and router table.

Let me know if you have any questions and good luck.

Kyle
 

jaggudada

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Jun 21, 2010
Messages
41
Prefill the "spalled" areas with a self leveling epoxy or epoxy patch material.
Flat blade the material with a squeegee.
Then coat with a good 100% solids epoxy coating.

Any recommendation on self leveling epoxy or epoxy patch material?
 

AlphaGarage

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Apr 16, 2008
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Every Garage, AnyTown, USA
We have a 100% epoxy binder, TrowelEase. You combine it with 50 pounds of sand and trowel away. It's self-priming, and there's no need to wait 28 days before coating. When cured it adheres to the substrate very, very well, and is extremely durable, it's used in heavy load areas, like fork lift traffic and the like.

Those acrylic modified concrete patching products are a quick fix and not even close in strength to any of the TrowelEase products.

With sand the 1 gallon kit with fill a 16 square foot area approx 1/4" thick. Depending on the sand used and the technique, it's pretty smooth and doesn't need any additional sanding, but should be coated.
 
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robmack

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Jul 16, 2010
Messages
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Location
Toronto, CANADA
Thanks to all for your valuable input.

Maybe go Race Deck
As for RaceDeck, I found out that the loading capacity of the tiles is 250 pounds per square inch. The woodworking machine on mobile bases exert somewhere between 75 - 120 KG per square inch. If the machine is loading the mobile wheel at 75 KG per sq. inch, then I'm OK with RaceDeck. At 120 KG per sq. inch, I'm pushing the limits of RaceDeck and would be better advised to go with epoxy.

We have a 100% epoxy binder, TrowelEase.
Prefill the "spalled" areas with a self leveling epoxy or epoxy patch material.
I'd like to use Wolverine epoxy coatings and Towel Ease epoxy-base patching however, this product line is not available in Canada AFAIK. I've not been able to source an epoxy based filler. Importing this would be prohibitively expensive. I'm only left with acrylic-modified cement products available at the local building supply houses which don't have the same strength. Does anyone know a place in Canada (Ontario prefered) that sells epoxy-based patching products?
 
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