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Garage Expansion - Concrete Floor Question

hughfree

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Aug 30, 2011
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125
Location
Fayetteville, GA
I am expanding my garage from 20' x 20' to 20' x 32'. My plan is to finish the floor with an epoxy finish after curing. The garage will be used shop for my automotive and fabrication projects. My permit has just been issued and my contractor plans to pour the slab extension next Tuesday or Wednesday.

My question for the concrete floor experts:
1. How many control joints should I need?
2. How should the cold joint between the old and new slabs be finished.
3. What should I look for regarding reinforcement (wire mesh, rebar)
4. How should the slab be finished for best results with epoxy

Thanks for the help!
 
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ConCretin

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Jan 20, 2011
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Central Maine
A couple additional points to consider. I'd make sure the extension is supported by a stable sub-base and I'd pin the extension to the existing slab with #4 bars @ 12" OC. If your thinking epoxy, you'll need a good vapor barrier - hopefully the existing slab has one too. With regard to your questions;

1. How many control joints should I need?

One in the 12' direction should be fine but make sure you continue any existing CJs into the extension

2. How should the cold joint between the old and new slabs be finished.

I'd just open it up a bit to allow for caulking - you'll likely get some movement.

3. What should I look for regarding reinforcement (wire mesh, rebar)

Either is fine. Just make sure it is properly supported so it doesn't end up sitting on the ground.

4. How should the slab be finished for best results with epoxy

The epoxy guys will have additional info on this but I'd opt for a 'shark skin' finish - think 100 grit sandpaper.

Hope this helps - Good luck with your build.
 

JimVonBaden

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Dec 2, 2011
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15,716
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Northern Virginia
Great questions and answers. I am planning, in a year or so, to do the exact same thing (size and all), and this is good info to have.

OP, make sure you post a thread on the build, with lots of photos!

Jim :cool:
 

dcs Inc

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Dec 13, 2010
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803
Location
Indianapolis, Indiana
I'll start off saying I really dislike a homeowner telling me my business so I'd walk lightly telling this guy he should do this and that. (Suggest) and ask if this would be better.

Will this area be constantly heated? If so: Cold joint the slab with no expansion joint material. Later you will use a crack chaser and epoxy fill. Drill holes every 4' or so and install dowel rods. (1/2" rebar about 16" in length). Drill about 4" into existing sidewall of concrete. Use 1/2" rebar as a cage running both directions for the slab reinforcement, wire tied and on ladders raised into the middle of the pour. I like a 6 bag mix, no air entrainment, 4" slump with water reducer additive over a 10 mil vapor barrier plastic. Follow the expansion cuts that are in the existing slab. Since this will be a 12'x20' extension, one down the center should be enough. (At least). If saw cutting these, make sure they are installed as soon as you can walk on the slab. Waiting too long and they become "faux" decorative cut lines.

As far as the finish, if power troweled, have the guy finish the slab with float blades. he can get a good finish with these and not overly glaze the top. If hand finishing, trowel finish should be fine. Never add water to the surface during finishing.... it weakens the cement matrix and will cause a soft surface.

If you are in a hurry for this to hydrate the contractor can add a "high early" additive into the mix. This speeds hydration but it also shortens the working time to finish. (Be careful because on a hot day it really becomes a PIA to place and finish).

Take care on the cold joint. Sometimes it may require a light grinding at the edge of the existing to make smooth for the placement of the new concrete. (Ridges, raised areas) Hand float/trowel for an even finish.

If not heated: Install an expansion joint material. The foam board verses the black tar impregnated is better. The foam has a top strip that can be removed for a filler to be applied on it when the concrete is finished. ( I can't remember) the expansion joint material's name is as it may not be called foam board) It's the plastic looking stuff. It comes in a roll. Light grey or black.

In a perfect world, 16" on center for the rebar grid. Also, if not heated, the expansion joint material could be used around the perimeter. (Again, in a perfect would).

The BIGGEST thing is to have the granular fill compacted REALLY well. I don't like pea gravel because it moves around too much when placing concrete. Sand is just OK if it's kept wet at placement but that becomes tough if you have a vapor barrier installed. Crushed stone with fines is great and compacts well.

In any case, after the concrete has dried out enough to apply epoxy, I still would recommend shot blasting or at least spiral grinding the surface.
 
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hughfree

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Aug 30, 2011
Messages
125
Location
Fayetteville, GA
Thanks guys for the input.

DCS...I appreciate your insight. I am definitely not interested in telling my contractor how to do his job. My concerns are, as with any consumer, I am spending a large sum of cash in an area that I do not have an expertise. If my contractor gets mad or upset because I am asking questions about the process...I picked the wrong GC. I only get one chance to do this right the first time. Thanks for reminding to be tactful.
 

dcs Inc

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Indianapolis, Indiana
Seems anybody (everybody) is a concrete finisher these days. Proper insurance, license and references are a must. Request a copy of the delivery ticket from the concrete supplier before the concrete is delivered. Run a string line across the floor to check for thickness when final grade and compaction of base is done. Make sure absolutely no water is applied to the surface anytime during the finishing phase.
 
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