Metallic Epoxy Floor Imperfections

[750CC]

Hi folks,

New member here, but have been reading various posts on the forums over the past few months as my fiancé and I tackle our detached garage renovations.

Recently we had the flooring done in a metallic epoxy but aren’t sure on the quality of the finished product. Hoping to get some input from those of you with more experience with this sort of thing.

The garage is roughly 20’ x 24’ with original flooring made up of 4 sections of concrete (split by what I believe are called saw cut control joints).

Our main observations of concern:

1. Imperfections from bubbling (photos attached);

2. Debris on the surface of the product - for example wood chips (photo attached) and other bumps on surface that feel like grit but aren’t intentional in terms of slip grip;

3. Some left over visibility of the concrete saw cut joints. The joints are filled and the surface level smooth, but we can still see where the joints exist under the coats;

4. Dripping through the sill of the door onto the front concrete (photo attached). This is my fiancé’s primary concern because we don’t want to get into painting the concrete and have to worry about matching the rest of our home that’s uniform with the garage.

Are any of the above in your experience to be expected, or definitely not acceptable for a finished product? We can appreciate nothing will be completely perfect given the tedious nature of the epoxy application but we’re trying to gauge what is acceptable and unacceptable for the finished product.

Appreciate your input.

Corey

 

[Kaizen]

Lets back up a few steps. How did they prep the floor?
You just recently had this done you say but you are in canada? What temp was this done in?
Your door was installed without good caulking under it so it flowed under. you can mechanically remove it or see if they will.
Air bubbles do show if they did not use a primer coat. The primer helps fill all the holes so the top coat of epoxy wont have as many. still will have a few.
If it was windy the day they did it then that might explain the wood chips. When i did mine i put down a tarp so i didn't track anything in. Looking at that blacktop i'd have hosed the heck out of it so it reduced the amount of dirt and debris.
The control joints will telegraph through. After a few winters if you have freeze temps don't be surprised to see small cracks over those joints.
I'd call whoever did it and tell them you want them to redo some parts of it. see what they say.

 

[750CC]

Thanks for the reply! Sounds like some of the imperfections are passable given the conditions.

I’m not entirely sure of the prep process but I know they sanded the whole floor and filled the joints before applying any layers. They did 3 layers total - base (I think considered primer), flood coat, and then the high traffic top coat with some slip resistance.

I am in New Brunswick, Canada so the outside temperatures were definitely a challenge. It was completed over a span of about a week including time to cure. Temperatures dropped well below freezing at times. The company did mention afterward that it was a particularly difficult job, although they’re local so I would imagine they’d be used to winter weather.

I think you’re probably right on the wind / debris. There was a tarp put up to seal off the project but they were having trouble getting the base layer to dry so had to setup a propane heater. We did have an electric heater hanging from the ceiling from the beginning which kept the space at room temp but once the garage door was open it didn’t seem to be enough. The propane heater at the edge of the door probably blew in some debris from the driveway.

Is it a major process to remove some of the more noticeable debris and air bubbles? And as for the leakage outside the door, any suggestions on how to remove that?

 

[Kaizen]

Thanks for the reply! Sounds like some of the imperfections are passable given the conditions.

I’m not entirely sure of the prep process but I know they sanded the whole floor and filled the joints before applying any layers. They did 3 layers total - base (I think considered primer), flood coat, and then the high traffic top coat with some slip resistance.

I am in New Brunswick, Canada so the outside temperatures were definitely a challenge. It was completed over a span of about a week including time to cure. Temperatures dropped well below freezing at times. The company did mention afterward that it was a particularly difficult job, although they’re local so I would imagine they’d be used to winter weather.

I think you’re probably right on the wind / debris. There was a tarp put up to seal off the project but they were having trouble getting the base layer to dry so had to setup a propane heater. We did have an electric heater hanging from the ceiling from the beginning which kept the space at room temp but once the garage door was open it didn’t seem to be enough. The propane heater at the edge of the door probably blew in some debris from the driveway.

Is it a major process to remove some of the more noticeable debris and air bubbles? And as for the leakage outside the door, any suggestions on how to remove that?

Sounds like they at least did the steps correctly which is good. imo you should know and monitor all of the work so if you see them skipping a step or you don't like something you can call them out on it. Just a good thing in life. If you are not doing the work at least educate yourself on it.
I would have waited till warmer better weather. I imagine you had to get this moving to get stuff in. They would have to sand and recoat at least that area. Hopefully its just in the clearcoat. If they do have to redo the clear have them double up on the slip resistance. I live in snow country as well and have never slipped even with snow caked in my boots. The first time the wife falls you will realize my wisdom.
Those drips should be able to be chipped or ground off with a wire wheel on a grinder. I'd def ask them to fix that as well.
Welcome aboard

 

[FMB4]

Welcome aboard! That said, what you show is lousy work imo. I looks like the crew didn't mix the epoxy thoroughly and those runs from the threshold are completely unacceptable. Not sure if I'd want that crew/company on my property for any reason after seeing those photos.

Have good New Year, and we hope things go better for you!

 

[Bucko]

Something another guy said in a previous thread about painting was the best way to have a great paint job was to get the furniture back in as soon as possible.

It looks like the area below the threshold is bare concrete. If the runs are thick you could hit it with a flap disk and color match some paint to hide it. I would get some paint on that door trim as well before it rots out.

Unfortunately if you call the crew back out, short of a recoat you will always see imperfections in your mind once its there. Maybe you could get a partial refund?

Its also hard to guage just how big the bubbles are. If you throw a quarter down it will give a size reference.

 

[750CC]

Thanks again for the input everyone! I’m going to contact the company to discuss where to go from here. At least now I have some outside knowledge to backup my concerns.

I’d like to have the spots corrected, but as pointed out, I’ll probably always notice the fixes. Also worried that having the same guys do the work may result in more headaches. I suppose I’ll gauge what to do based on their response, which may end up being to pursue a partial refund…

The finished floor isn’t terrible but the reactions so far confirm my initial feelings. Definitely a little sloppy in areas.

I would have preferred to wait until the weather improved. Unfortunately the project was already pushed back and then of course we’re in a rush to finish the cabinetry, etc. so that we can get it functional and have things back in there before the snow really piles up. Been lucky so far in that respect.

If anyone else in a similar situation comes across this thread - I will echo the warmer weather recommendation. Save yourself the extra complications if possible.

Anyway we’ll see what happens from here. I’m hoping the other stages of the reno will go a bit better!

 

[Armorpoxy]

All coatings flow less as the temperature gets colder...as a general rule we would not recommend applying a metallic system when it is cold outside and or the slab was cold, it could prevent the metlallics from blending like they are supposed to.

The front lip as per above ok to sand or grind it off. Sloppy.....