Introduction

Concrete has been a go-to building material for centuries, known for its impressive durability, it plays a critical role in both industrial and commercial constructions. But over time, exposure to wear and abrasion and harsh conditions can affect its strength and integrity. To help extend its lifespan, protective coatings and epoxy mortars are commonly used.

One of the biggest challenges when applying these coatings and mortars is improper surface preparation, which can lead to problems like flaking, pinholes, and poor adhesion. In this guide, we’ll cover some of the best practices for preparing concrete surfaces and highlight how using high quality Devcon flooring products can ensure the best possible results.

Assessing the Condition of the Concrete

When applying coatings and mortars to concrete, the most significant obstacle is often inadequate surface preparation, which can result in issues like flaking, pinholes, and poor adhesion. Before going deeper into the concrete surface prep process, start by assessing the current state of the concrete. To achieve optimal results, look for cracks, pits, stains, or areas that have been damaged due to heavy traffic or exposure to chemicals. If you’re performing concrete repairs, identify the underlying causes of the damage to ensure a long-lasting solution. Make sure that there are no deep contaminants that may have been absorbed by the concrete compromising its structure.

Clean the Surface Thoroughly

One of the most crucial steps in concrete surface preparation is cleaning the concrete thoroughly. If the concrete surface is not properly prepared, you may experience issues with adhesion to the concrete, peeling, delaminating, or cracking of the coating. Dirt, oil, grease, and other contaminants can prevent coatings from bonding properly. Use a pressure washer or a suitable cleaning agent, depending on the severity of the contamination. If necessary, use a degreaser to remove any stubborn stains.

Remove Old Coatings and Sealers

If the concrete surface has been previously coated, the best practice is to remove any old concrete sealers or paint. This ensures that new products, like epoxy flooring, adhere properly and deliver the expected performance. Mechanical methods such as shot blasting, UHP Water Blasting or diamond grinding are highly effective for this process.

Repairing the Worn Concrete

If you’re repairing cracks or holes in concrete, now is the time to use Devcon flooring products or rapid curing cement mortars to patch holes voids and to produce a regular surface and prevent further deterioration. These products are designed to restore concrete strength and integrity. Make sure to follow the manufacturer’s instructions for curing and application.

Surface Profiling

To ensure strong adhesion between the concrete and any coatings, surface profiling, which involves roughening the concrete surface to create optimal mechanical interlocking points for the coating to bond with, is key. This should be done by following recommended standards, such as below, to guide you through the ideal profile depth and/or shape.

Devcon Epoxy Flooring Systems Recommended Standards:

Epoxy Mortars:

• Atmospheric: SSPC-SP13/NACE 6, or ICRI No. 310.2R, CSP 3-5
• Immersion: SSPC-SP13/NACE 6 – 4.3.1 or 4.3.2 or ICRI No. 310.2R, CSP 3-5

Epoxy Sealers and Coatings:

• Atmospheric: SSPC-SP13/NACE 6, or ICRI No. 310.2R, CSP 1-3
• Immersion: SSPC-SP13/NACE 6-4.3.1 or 4.3.2 or ICRI No. 310.2R, CSP 1-3

Conclusion

Proper surface preparation is essential for achieving a durable and high-performance concrete surface. By following best practices, you can be confident that your concrete surfaces are ready to be coated with epoxy flooring, chemical resistance coatings, and epoxy mortars. If the goal is floor durability, don’t forget to choose the right Devcon flooring products. If working with secondary containment coatings always consider the specific needs of your industrial environment to achieve the best results. Whether you’re performing general concrete repair or installing new industrial flooring solutions, thorough preparation is the key to success.