
Transforming Ordinary to Art with Epoxy Flooring Systems
Advanced epoxy flooring systems offer a versatile solution for mitigating issues, revitalizing spaces, and enhancing the aesthetic appeal of concrete floors. Keith Kimberlin, owner of Surface2Surface Global (S2S), a manufacturer and installer of liquid polymer and decorative concrete products, has achieved significant success in providing unique concrete flooring solutions. His work has gained recognition through appearances on television shows like Discovery Channel’s "Garage Rehab" and NBC’s "Cash Pad," which showcase the transformation of various properties into attractive and functional spaces. The increased demand for S2S’s services, following these broadcasts, led Kimberlin to establish a global dealer network, enabling him to share his proprietary methods and products with other concrete resurfacers.
Customers typically consider five key factors when selecting a floor system: cost, aesthetics, longevity, durability, and maintenance. S2S’s advanced floor systems address these considerations, as demonstrated in various projects completed in spring 2019. One notable application was the Endura-Top 550 system at Raytheon Intelligence and Information Systems in Springfield, Va. This four-part, self-leveling polymer-modified urethane concrete system, applied 3/8 inch thick, is designed for extreme environments. It offers high resistance to impact, abrasion, chemicals, and thermal shock, and is particularly effective in addressing concrete moisture issues. The system repairs damaged concrete by patching cracks and applying the Endura-Top layer, which effectively replaces the existing concrete surface. The coating is applied with a gage rake and broadcast with No. 30 sand for strength and slip resistance, then sealed with a polyaspartic urethane topcoat, which represents the latest in flooring technology.
The primary reason for Raytheon’s selection of Endura-Top was to mitigate a persistent moisture problem that had caused previous coatings to fail. Concrete, being porous, can absorb and transmit moisture, especially if placed without an adequate vapor barrier. This moisture migration can lead to efflorescence, a white powdery residue that compromises the bond of traditional epoxy coatings. Endura-Top stands apart from conventional “lock out” systems by being breathable, possessing unlimited moisture vapor emission resistance (MVER). This characteristic allows moisture to pass through the coating without causing bubbling or delamination. In the Raytheon project, an additional layer of S2S CPT-3500, developed by Aquron Corporation International, was applied. This product penetrates the concrete and forms a gel upon contact with moisture, effectively blocking water from reaching the surface and providing a critical solution for hydrostatic pressure issues.
Another innovative application involved a new 12,000-sq.-ft. automated self-storage facility in Spring, Texas, called EZ Werks Self-Storage. The facility’s lobby featured S2S Metalloid Epoxy, a proprietary dynamic flow 3-dimensional metallic epoxy floor coating that creates a multi-dimensional, multi-color acid stain appearance. This high-end solution, applied 3/16 inch thick, is suitable for showrooms, art galleries, and other upscale environments. For the common areas and hallways, a micro-blend flake system was used. This system, consisting of a 100% solids base coat epoxy with a 1/8-inch polymer flake broadcast, offers superior durability, ease of maintenance, and resistance to chemical exposure, impact, and abrasion. Flake floors are a popular choice due to their ability to conceal daily dirt and dust, making them easier to maintain in commercial settings.
Regardless of the chosen floor system, proper surface preparation is crucial for the successful application of epoxy coatings. S2S emphasizes the importance of evaluating the concrete’s condition, patching any damage, and achieving a Concrete Surface Profile (CSP) of at least two. This texture, typically achieved using industrial grinding equipment or shot blasters, is essential for the coating to bond correctly. Unlike power-troweled concrete, which is too hard for effective bonding, the open surface created by grinding allows S2S’s proprietary epoxy to penetrate the concrete like an oil lantern, utilizing a chemical that facilitates a migratory response. This wicking technology allows the product to become an integral part of the concrete, distinguishing it from conventional epoxies that merely sit on the surface. Therefore, while surface preparation is generally important for all products, it is mission-critical for the optimal performance of S2S’s systems.
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