Installing a Double Broadcast, Decorative Micro-Chip Floor System
We were contacted by a local food manufacturing plant to improve their existing bathroom floor. The existing floor was the same floor that had originally been installed when the facility was built. Typically, with new construction, General Contractors seek the least expensive subcontractors to complete the work. There is a compromise when seeking the least expensive subcontractors, and it’s typically quality in work. During the site visitation, it was apparent that the cove was subjected to serious “sagging,” meaning that an epoxy, with insufficient viscosity properties, was used to trowel the cove. The customer had been displeased with the appearance for a while, and requested a new cove to be installed, and expanded from 4″ to 8″.
We began the project by abrading the floor with 7″ hand grinders. The existing floor, although unsightly, was well adhered to the concrete, relieving us from the need to grind off the floor. To handle the cove, we needed to remove a row of tile above the existing cove. Using a 4″ cut wheel, the installers cut around the grout of the tile, to allow for clean removal. Then using an air chipper, the installers carefully chipped out the tile, careful not to chip or crack the row of tile above.
Then, we need to infill the void with an epoxy mortar. An epoxy mortar consists of heavy aggregate, such as sand and sometimes pebble or stone, and epoxy. The mortar needs to have a high level of viscosity to mold into the void. Once the void was filled, the next step, before troweling the cove, was to prime and saturate the cove and infill with a low viscus epoxy mix.
Installing the Micro-Flake, Double Broadcast, Decorative Epoxy Floor
After the cove was prepared, it was time to install the decorative double broadcast flake floor. The customer opted for a double broadcast floor. The benefits of a double broadcast is that it has an opportunity to cover up any imperfections that may be apparent with a single broadcast. The chosen broadcast material was a 1/16″ micro-flake. The micro-flake is visually comparable to a quartz broadcast floor system. However, it is easier to handle, not nearly as heavy, provides almost the same level of slip-resistance, and costs a little less than the quartz, due to its reduced weight.
After the double broadcasts have been installed, the installers grouted over the floor 3 times. The first 2 grouts were a polyaspartic. The reasoning for the polyaspartic is that it doesn’t amber or yellow. Epoxies are unstable and can yellow or amber over time, which can impair the floors appearance. Polyaspartics don’t possess this limitation, and can offer color stability that customers seek. It doesn’t come at an increased cost, but the customer was willing to pay for the additional feature for the installation. And the final grout was completed with an aliphatic urethane wear coat to protect against abrasion and chemicals.
The final floor was completed on schedule and under budget. The installers really pulled through with their skills and trade, to install a very nice floor, that ultimately left the customer very happy with the installation.
PennCoat, Inc has provided industrial painting, commercial painting, epoxy flooring, and polished concrete services for nearly 30 years. We service in Pennsylvania, Maryland, New Jersey, and Delaware. Contact us today for your flooring or painting project.