Fix garage floor to epoxy

[nelsonuwp]

Hey guys I'm looking to epoxy my garage floor but it seems to be in pretty rough shape (17 years of salty Wisconsin winters) and I'm looking for some ideas to fix it (to prep for epoxy). Here's what I'm dealing with. It's like this in a few different spots, looking for any ideas. Thanks in advance.

Close-up

 

[Wingnut65]

Welcome to GJ, nelsonuwp. Looks like a grinder and some knee time is in your future plans... Search under this Flooring section and there are many projects that had floors in the same condition as yours. Here is how Big Boi did it: http://www.garagejournal.com/forum/showthread.php?t=66376

Action shot:

He has all the info on the grinder set-up in his thread.BUT, use knee pads... They are cheap enought at HF.

This seems to be the best way to get the floor prepped to what is needed. And its a lot cheaper than overlaying with a thinset leveling concrete. Even then, it would need to be scuffed up to have the epoxy bond to it.

How extensive is this condition? Actually, how big is your garage?

Good Luck with your project.

 

[nelsonuwp]

The garage is 19'x19', but there is probably only 10 sq. feet of floor like this in an outline of a car. I just bought the house so I'm assuming the salt/snow from the winters eroded it away (guess) .

Further more, I'm in the process of taping and mudding the drywall and plan on installing lights this weekend, so fortunately the floor is a month out.

Question:
Do I need to grind the entire, floor? It looked like he did and if not, what do you do with the pits the grinding will create?

 

[AlphaGarage]

You can use a epoxy mortar binder mixed with sand the spread over the rough area and level it out to match surrounding grade.

We carry "TrowelEase 1161" for that purpose. A one gallon kit is mixed with 50 lbs of locally sourced sand, it's self priming so it's applied directly to the rough spots, it will cover approx 15 ft2 1/4 inch deep. Then you feather it out, allow it to cure (4 - 24 hrs) and overcoat.

If you're a bit unsure about your ability to feather it out smooth enough, plan on some flakes and you should be fine.

 

[regguy1]

Research 2 products: Ardex and Norcrete, I haven't used them but they've been mentioned regarding this condition.

 

[karsty]

Try a product from Mapei called Mapecem Quickpatch. It can be trowelled on from featheredge to 3" thick. I plan on using that in the low spots on my garage floor, sanding it smooth, then coating the whole floor in epoxy or a polyurethane coating.

Been talking to professional concrete restoration companies and this is what they suggested as a product that won't break the bank, but will be durable and smooth out any low or rough spots.

 

[LegacyIndustrial]

If you are planning to use an Epoxy Coating on the floor. Mix a small amount prior to coating the entire floor. Mix in some fine sand or aluminum oxide to the coating and coat over the rough spots. If you you use a "high build" epoxy coating ( not The Home Depot stuff) . When you are happy with the texture you can then coat the entire floor, making sure to scratch up the areas you smoothed out. Try http://legacyindustrial.net/cart/epoxy-coating-hd707-self-leveling-15-gal-p-22.html

-Scotty

 

[LegacyIndustrial]

Lastly, do not use ARDEX or other cementitious topping on a garage floor. The first time you drop a hammer or jack over it you will get a failure. That stuff is good for sidewalks, not impacts. If you want an impact resistant patch that you can trowel into the spalled areas try : http://legacyindustrial.net/cart/epoxy-concrete-patch-1-gal-hd110-p-6.html
Use less sand and you can "self-level" it.

-Scotty