To avoid these ads, REGISTER NOW!

New Epoxy Garage Floor Project

SunsetsAndFriends

Well-known member
Joined
Sep 10, 2012
Messages
753
Devoe Epoxy/Legacy Industrial Garage/Shop Floor Project

Well, I hired a "contractor" to pour my 425 sq ft garage/shop floor in the spring of 2014. Usually, I do my concrete work but because I did not have any helpers, I decided to hire it out. I should have done it myself. The "contractor" did not put in all the necessary control joints, so the slab cracked in the field in several places. There is rebar throughout which helps.

I specified a smooth, troweled finish as I didn't want any kind of coating. Since the "contractor's" skills were lacking in this department, I'm coating.

I ground the floor using a rented 10" floor grinder from HD. And I also purchased a 7" Diamabrush and shroud from Scotty at Legacy Industrial. The Diamabrush works very well. For as much as I used it, it is still almost new.

Here's a picture of the garage. Notice the floor drain not properly finished out and the protective tape still attached. Not very professional.

Initial Plan:

1. Grind floor.
2. Chase cracks and fill with Xtreme Set 100, which I purchased from Scotty at Legacy Industrial.
3. Prime coat.
4. Money coat with flake.
5. Clear coat.

Actual Execution:

1. Grind floor.
2. Chase cracks and fill with Xtreme Set 100, which I purchased from Scotty at Legacy Industrial.
3. Fix floor drain.
4. Score/grind to level approach and threshold.
5. Acid etch using a floor maintainer/diamond impregnated brush and hydrochloric acid.
6. Five coats of silver gray Devoe Devran 224v surface tolerant, 77% solids epoxy.
7. Flake with 17 pounds of blue/black/gray/white custom blended flake.
8. One coat of Devthane 379 clear two part urethane.
9. Final coat of Devthane 379 clear two part urethane w/ Shark Grip.


The grinder from HD ended up being less useful than I thought and after the fiasco at HD, I should have rented the Diamabrush and Floor Maintainer instead. The fella rented the 10" grinder for $85 per day. So I paid my $150 deposit, and I took it as a more economical option. When I returned it, the clerk claimed I owed another $50. After some discussion, he said I was being charged for the machine and the diamond wheel. Well, that wasn't explained to me up front and I even made a point of asking whether I would be able to return it within four hours and only pay the 4 hour rate. The clerk told me that I would then only pay $59. Needless to say the manager of the store helped me out. But had the clerk explained up front prior to renting, I would have taken the Diamabrush instead.
 

Attachments

  • 00 Start.jpg
    00 Start.jpg
    32.4 KB · Views: 239
  • 00 Start - Flake.jpg
    00 Start - Flake.jpg
    161.9 KB · Views: 217
Last edited:
To avoid these ads, REGISTER NOW!
OP
S

SunsetsAndFriends

Well-known member
Joined
Sep 10, 2012
Messages
753
My garage is under my house. The garage floor level, though, is actually about 12" higher than street level. I performed a moisture test after grinding the floor - 3' x3' plastic taped on all sides. After 24 hours, bone dry.
 

Attachments

  • 6 H2O Test.jpg
    6 H2O Test.jpg
    144.1 KB · Views: 99
Last edited:

G8rDuc

Well-known member
Joined
Feb 19, 2014
Messages
116
Location
Gainesville, FL
Nice post. I'm about to build a 30x30 on top of an old half-basketball court and I need to get rid of the paint and prep, so I'm thinking about going to HD to rent the Diamabrush with the grinder. Did you do it wet or with a vacuum?
 

LegacyIndustrial

ALLIANCE MEMBER
Joined
Jun 7, 2010
Messages
7,994
Location
deerfield, IL
Well, I hired a "contractor" to pour my garage floor about 18 months ago. Usually, I do my concrete work but because I did not have any helpers, I decided to hire it out. I should have done it myself. The "contractor" did not put in all the necessary control joints, so the slab cracked in the field in several places. There is rebar throughout which helps.

I specified a smooth, troweled finish as I didn't want any kind of coating. Since the "contractor's" skills were lacking in this department, I'm coating.

I ground the floor using a rented 10" floor grinder from HD. And I also purchased a 7" Diamabrush and shroud from Scotty at Legacy Industrial. The Diamabrush works very well. For as much as I used it, it is still almost new.

Here's a picture of the garage. Notice the floor drain not properly finished out and the protective tape still attached. Not very professional.

Plan:

1. Grind floor.
2. Chase cracks and fill with Xtreme Set 100, which I purchased from Scotty at Legacy Industrial.
3. Prime coat.
4. Money coat with flake.
5. Clear coat.

I haven't purchased coatings, yet, because I need to figure out colors.

The grinder from HD ended up being less useful than I thought and after the fiasco at HD, I should have rented the Diamabrush and Floor Maintainer instead. The fella rented the 10" grinder for $85 per day. So I paid my $150 deposit, and I took it as a more economical option. When I returned it, the clerk claimed I owed another $50. After some discussion, he said I was being charged for the machine and the diamond wheel. Well, that wasn't explained to me up front and I even made a point of asking whether I would be able to return it within four hours and only pay the 4 hour rate. The clerk told me that I would then only pay $59. Needless to say the manager of the store helped me out. But had the clerk explained up front prior to renting, I would have taken the Diamabrush instead.


Looks like a decent grinder. Did you purchase the dust deputy set-up or rent it? We use a similar version and it works awesome!!
 
OP
S

SunsetsAndFriends

Well-known member
Joined
Sep 10, 2012
Messages
753
Nice post. I'm about to build a 30x30 on top of an old half-basketball court and I need to get rid of the paint and prep, so I'm thinking about going to HD to rent the Diamabrush with the grinder. Did you do it wet or with a vacuum?


I ground dry. Dealing with a slurry sounded too much like work.


Sent from my iPhone using Tapatalk
 
OP
S

SunsetsAndFriends

Well-known member
Joined
Sep 10, 2012
Messages
753
Looks like a decent grinder. Did you purchase the dust deputy set-up or rent it? We use a similar version and it works awesome!!


The grinder, unfortunately, underperformed to my expectations. It took me 15 hours without edging. And I think the profile might not be good enough. It feels too smooth.

The Dust Deputy works great. The vacuum and DD I bought a couple years back and have served me well. After seeing how well the Pulse-Bac line of vacuums work, I would prefer one.


Sent from my iPhone using Tapatalk
 

LegacyIndustrial

ALLIANCE MEMBER
Joined
Jun 7, 2010
Messages
7,994
Location
deerfield, IL
The grinder, unfortunately, underperformed to my expectations. It took me 15 hours without edging. And I think the profile might not be good enough. It feels too smooth.

The Dust Deputy works great. The vacuum and DD I bought a couple years back and have served me well. After seeing how well the Pulse-Bac line of vacuums work, I would prefer one.


Sent from my iPhone using Tapatalk

I find that no matter which you choose, you have to keep moving your hoses a bit to keep the dust from building up. At least with concrete dust.

15 hours??? ouch. :sad:
 
OP
S

SunsetsAndFriends

Well-known member
Joined
Sep 10, 2012
Messages
753
I find that no matter which you choose, you have to keep moving your hoses a bit to keep the dust from building up. At least with concrete dust.

15 hours??? ouch. :sad:

Yes. 15 hours! Here is a photo. The right side shows the curing agent and the left side has the coating ground off using just a 7" Diamabrush, with the quarter in the middle.
 

Attachments

  • Coating Before After.jpg
    Coating Before After.jpg
    104.8 KB · Views: 273
Last edited:
OP
S

SunsetsAndFriends

Well-known member
Joined
Sep 10, 2012
Messages
753
Here are few images showing different levels of grind, but all with coating removed.

1. The left image shows what I think is a very good grind.

2. The middle image (quarter with a gold sheen) has an okay grind but not stellar.

3. The right image (bright, shiny quarter) shows that the pores of the concrete are not open enough.
 

Attachments

  • Grind Ok.jpg
    Grind Ok.jpg
    131.8 KB · Views: 178
  • Grind Good.jpg
    Grind Good.jpg
    134.2 KB · Views: 188
  • Grind Not Open Enough.jpg
    Grind Not Open Enough.jpg
    135.4 KB · Views: 196
OP
S

SunsetsAndFriends

Well-known member
Joined
Sep 10, 2012
Messages
753
I was unhappy with the level of grind from using the HD machine. So, I rented an Edco 3 diamond head machine from a local rental (not big box rental) store. As you can see from the picture, the Edco really grinds.

Usually the cost is $69/day for machine & $84/day for diamond heads. But here's the good deal: they have a weekend special where you pick up on Friday after 3 pm and return on Monday by 8:30 am and pay only one day.

The second photo shows after one pass. The third shows the grindings in a dust pan. And the fourth shows the area swept up. Notice the ground parts versus the "creamy" parts, which are small low spots due to a wavy trowel finish. I'll need to make another pass to even it out.

Already, I can tell a much more aggressive surface profile to accept a coating.
 

Attachments

  • 2 Edco.jpg
    2 Edco.jpg
    130 KB · Views: 218
  • 1 Pass.jpg
    1 Pass.jpg
    141.9 KB · Views: 239
  • 3 After One Pass.jpg
    3 After One Pass.jpg
    129.1 KB · Views: 203
  • 4 After One Pass.jpg
    4 After One Pass.jpg
    116.6 KB · Views: 224
Last edited:

Armorpoxy

Well-known member
Joined
Aug 18, 2013
Messages
3,735
Location
NJ
We love those Edco type grinders, they really do a nice job and are more aggressive than some other prep methods. There is nothing like a good set of diamonds and some downward weight to get the job done!
 

benwah

Well-known member
Joined
May 21, 2014
Messages
980
Location
Crested Butte, Colorado
Here are few images showing different levels of grind, but all with coating removed.

1. The left image shows what I think is a very good grind.

2. The middle image (quarter with a gold sheen) has an okay grind but not stellar.

3. The right image (bright, shiny quarter) shows that the pores of the concrete are not open enough.


Pic #1. ICRI-CSP 2 maybe 3 (too small an area to tell properly)

Pic #2. ICRI-CSP 1

Pic #3 ICRI-CSP 1 at best
 
OP
S

SunsetsAndFriends

Well-known member
Joined
Sep 10, 2012
Messages
753
Pic #1. ICRI-CSP 2 maybe 3 (too small an area to tell properly)

Pic #2. ICRI-CSP 1

Pic #3 ICRI-CSP 1 at best

Thank you for your input. I was able to regrind my entire floor, going over it three times. I'll post some more pictures of the profile when I get a minute.
 

Slowgsr

Well-known member
Joined
Nov 14, 2014
Messages
610
Location
Southern ontario
I used a husqvarna pg 280

It's a single disc, diamond inserts. I did 800sq ft in about 5 hours - I got up 5 5gal pails of dust - it was high speed (direct drive) and kicked up a lot of dust. 2hp. I wanted the 2 disc edco but it wasn't in, I was skeptical but the single disc one worked very well

I had one section of my floor that was new, well 6mo old. It ground very quickly compared to the rest of the slab which was very very smooth and 40yr old. It was tough to break through the surface.

A good diamond grinder is worth the rental for prep. Especially with an old floor, concrete gets harder with age.
 
OP
S

SunsetsAndFriends

Well-known member
Joined
Sep 10, 2012
Messages
753
I used a husqvarna pg 280

It's a single disc, diamond inserts. I did 800sq ft in about 5 hours - I got up 5 5gal pails of dust - it was high speed (direct drive) and kicked up a lot of dust. 2hp. I wanted the 2 disc edco but it wasn't in, I was skeptical but the single disc one worked very well

I had one section of my floor that was new, well 6mo old. It ground very quickly compared to the rest of the slab which was very very smooth and 40yr old. It was tough to break through the surface.

A good diamond grinder is worth the rental for prep. Especially with an old floor, concrete gets harder with age.

My concrete is quite hard. The Edco seemed to work fine, though I suspect there is no comparison to a larger commercial machine.

When I have a minute, probably tomorrow, I'll take/post a few pictures of the profile achieved. I hope it's enough.
 
OP
S

SunsetsAndFriends

Well-known member
Joined
Sep 10, 2012
Messages
753
Well, I ground the floor again. Here are four pictures of the grind profile from four different areas of the floor. The floor feels smoother to the touch than I expected. I hope it's enough of a grind. This is my first project grinding concrete in preparation for a coating.
 
To avoid these ads, REGISTER NOW!

rene.merrild.7

Well-known member
Joined
Mar 17, 2014
Messages
73
You did the right thing to grind it all down. Wish I did that as well...

I painted my floor with a brand called Hempel. (Normally used for vessels)

First layer I used an epoxy coat with 40% thinner. Because I was afraid the paint was too thick to sink down in the concrete.

Second layer was the same epoxy coat without any thinner.

Last layer was an polyurethane paint. Without thinner as well...

I got a very strong floor, but dirt+water gets tracked in the small bumps.

Again... Great job.!
 

Duffey

New member
Joined
Oct 4, 2009
Messages
1
Location
Anderson SC
Wow that floor looks well prepped, like legacy said the dust deputy is a life saver with concrete dust. I always use one with my handheld grinders! A coating will have no problems adhering to that floor.
 
To avoid these ads, REGISTER NOW!
Top Bottom