RockSolid floor project

[56nash]

Well I was one of the lucky free install "winners". The odyssey began back in December when I was selected as one of the lucky 10. Our floor was a trainwreck, we had no choice but to repair it and soon. Our slab is the ceiling for our downstairs garage, so simply removing and re-pouring was out of the question. We had a bunch of damage from years of road salt eating up the slab and getting down to the rebar. This is what we found when the first chunk was popped out.
http://i190.photobucket.com/albums/z64/grumpy_old_man_photos/IMG_0225.jpg
http://i190.photobucket.com/albums/z64/grumpy_old_man_photos/DSC01569.jpg
http://i190.photobucket.com/albums/z64/grumpy_old_man_photos/IMG_0242.jpg
We began with a product recomended by Scott at Legacy to fill the cracks and stabilize what remains.
http://i190.photobucket.com/albums/z64/grumpy_old_man_photos/IMG_0254.jpg
Then we began with filling te rest of the hole with 100% solids epoxy filled with 40 grit sandblast sand.
http://i190.photobucket.com/albums/z64/grumpy_old_man_photos/IMG_0264.jpg
When all was said and done we had about 4.5 to 5 gallons of epoxy and 100 lbs of sand in that hole. My son and I began the process of grinding the floor with an EDCO 10" turbo grinder, that is another disaster altogether. My son who is a real trooper spent many, many hours over the course of a week grinding the floor by hand with a 7" diamond cup wheel to fix what the big grinder messed up.
There was a lot fo previous damage that had been patched, those areas are what in the long run caused us the greatest grief.
http://www.garagejournal.com/forum/picture.php?albumid=1046&pictureid=8575
http://www.garagejournal.com/forum/album.php?albumid=1046&pictureid=8576
http://www.garagejournal.com/forum/album.php?albumid=1046&pictureid=8577
http://www.garagejournal.com/forum/album.php?albumid=1046&pictureid=8578
http://www.garagejournal.com/forum/album.php?albumid=1046&pictureid=8579
http://www.garagejournal.com/forum/album.php?albumid=1046&pictureid=8580
And after the product was all down you could see the irregular blotchy areas, at first I was bummed, but this is so much better than it has been and I can clean and take care of the floor so much easier.
http://www.garagejournal.com/forum/album.php?albumid=1046&pictureid=8581
And now we have it all filled back up, don't know if we can fit any more in there

 

[slickgt1]

Looks good. Don't be bummed out. Better that what you had, and most of it will be covered with garage stuffs anyway.

 

[PaulR]

Still looks like a great transformation to me.

P

 

[56nash]

When we moved in to this house 9 years ago, it was a carport upstairs with a garage below. The only reason the carport even got turned into a garage by this point was the prying eyes and bitchiness if one old widow across the street that constantly bitched about the eyesore car she had to look at. The eyesore car was my 68 Cuda that was a restored trophy winning car. So the garage got framed and sided and doors installed but there it stayed for 9 years. My priorities have been on other things for the past 9 years, 5 of which my parents lived with us in our basement, when they moved in we had to add a kitchen downstairs, pour a sidewalk from the second driveway to access the walkout basement level and really make the basement a separate residence. It felt like for 5 years life was on hold until we got through all that, now I can concentrate on living my life again. The only thing I felt like I accomplished for me was the restoration of that 56 Metropolitan in the last picture. I really look forward to getting cabinets built a dna bench so the projects that have been on hold for 9 years can resume. The best part is I have a supportive wife who wants to see this for me as much as I want it. She really just wants me to get the 43 5 piece doors for her new kitchen built soon. She has had cabinets with no drawer fronts or doors since August last year, but I have not had anyplace to setup shop to get the doors made, now I do.

 

[kywildcat]

I think it looks great Nash!! I know its not perfect, but I dont imagine anybody that does this for the first time does it perfect. Be proud of your floor.........I sure am proud of mine! Now we just have to take a year to see how it wears!!!!

 

[NextCoatings]

That's not nearly as bad as your post reads...not bad at all and a great ride sitting on it as well. I've got some stories with floors that would make you feel much better about yours. Seriously though, it does look good and with all things considered, it sounds like it could have been much worse.

Well done!

 

[56nash]

I can say this without hesitation, I am pleased beyond belief with the material and the ease of application. I on the other hand look back on the prep and repair process and think that was the hardest longest project in a long time. Tonight was the first night in a couple of months I and my son have sat and done nothing but veg on the couch, cold drink, and a remote in hand. Felt real good.

 

[mackdx]

To the rest of the guys who were part of the "Rock Solid 10"....

What was the consistency of your base coat? Mine was extremely viscous - almost to the point that it was impossible to roll out if you poured too much out of the bag (I ended up drizzling thin strings on the floor to combat this). I destroyed about 8-9 foam rollers in the course of rolling out 1200 sq. ft. during the process. As a follow up, I needed a little extra material to finish and Rock Solid graciously sent me another quart. This extra quart was much thinner and easier to work.

 

[930dreamer]

It turned out great, good job on the floor.

I have a spot on the front door threshold(concrete) that needs to be repaired, chunk cracked out etc.

 

[56nash]

for repair get hold of Scott at Legacy for repair materials, great stuff

 

[cgallery]

for repair get hold of Scott at Legacy for repair materials, great stuff

Those repairs do look very impressive to me. A job well done, if you ask me.

 

[kywildcat]

To the rest of the guys who were part of the "Rock Solid 10"....

What was the consistency of your base coat? Mine was extremely viscous - almost to the point that it was impossible to roll out if you poured too much out of the bag (I ended up drizzling thin strings on the floor to combat this). I destroyed about 8-9 foam rollers in the course of rolling out 1200 sq. ft. during the process. As a follow up, I needed a little extra material to finish and Rock Solid graciously sent me another quart. This extra quart was much thinner and easier to work.

Mine had a nice consistency to it, and rolled out fine. Mine came in Plastic containers, not the bags. I use 4 foam rollers for 4 kits, and mine worked out well.

 

[crf]

I just coated my new concrete last week, 1200 sq ft used 5 packs, it rolled on very smooth and easy. The consistency was a little thicker then latex paint. The temp was around 72 and the humidity around 65%. I went through four 9" rollers since they kept creeping off the end of the handle. If I were to do it again I'd use the larger roller where both ends are attached to the roller. Floor came out so nice it's amazing and to think I was really worried about doing this job. So simple the whole process was with fool proof mixing and dispensing of the bags.

 

[mackdx]

Wow. I must have gotten a "special" batch because this stuff was the consistency of roofing tar

 

[56nash]

Mine was like mentioned before by crf and kywildcat about the consistency of thick latex paint, rolled out really well and seemed to self level to a certain degree. It sounds like your had started to cure or mix was off or some other factor. Mine also was in a plastic bucket. I was able to roll out 600 sq ft with only one roller cover, it took about 1.75 hours to roll it out and broadcast the flake. No matter how hard we tried to get an early start on this Friday afternoon it didn't happen, we started rolling at about 6:30 PM and went to dinner at about 9 and were up at 1:30 AM to see if it had cured enough to start the clear coat. Not ready till 2:30 maybe 2:45, we were back in bed by 4 AM. Let me tell you I am getting to old for that kind of s&%$.

 

[kywildcat]

To the rest of the guys who were part of the "Rock Solid 10"....

What was the consistency of your base coat? Mine was extremely viscous - almost to the point that it was impossible to roll out if you poured too much out of the bag (I ended up drizzling thin strings on the floor to combat this). I destroyed about 8-9 foam rollers in the course of rolling out 1200 sq. ft. during the process. As a follow up, I needed a little extra material to finish and Rock Solid graciously sent me another quart. This extra quart was much thinner and easier to work.

I would say it was starting to cure too. Please post some pics!!

 

[kywildcat]

I just coated my new concrete last week, 1200 sq ft used 5 packs, it rolled on very smooth and easy. The consistency was a little thicker then latex paint. The temp was around 72 and the humidity around 65%. I went through four 9" rollers since they kept creeping off the end of the handle. If I were to do it again I'd use the larger roller where both ends are attached to the roller. Floor came out so nice it's amazing and to think I was really worried about doing this job. So simple the whole process was with fool proof mixing and dispensing of the bags.

Glad it went good for you..........please post some pics!

 

[mackdx]

I would say it was starting to cure too. Please post some pics!!

If that was the case, then it was curing in the bag as it was this way from the minute I opened them. Overall, it came out just fine with the exception of a few thick areas that I just couldn't roll out. I'll snap a few photos and post the results.