Epoxy Flooring – Double Broadcast Flake System in Lancaster, PA

When searching for a slip resistant floor in Lancaster, PA, the common solution is to add some texture, like sand or #54 aluminum oxide into the mixture.  Or, to broadcast the texture-making material onto the troweled or squeegeed floor.  But if the customer or floor owner is looking for a more aesthetically pleasing solution, then they can consider a flake broadcast floor instead.  A flake broadcast floor will offer a textured floor, with slip protection, but it can present a nice looking floor that isn’t as industrial as a 1 colored floor.

But the common hesitation with a chip-flake floor is the installation process.  It requires additional steps compared to a standard, self-leveling epoxy floor.  But PennCoat has recently installed a chip flake double broadcast floor in its own shop in Lancaster, Pennsylvania.

1. Grind the floor.

As always, the first step is to prepare the floor prior to installation.  There are many viable methods to preparing a floor, but our preferred method is a planetary grinder, due to its speed and power.

The large white spot in this picture is the foundation we used for the logo.  The challenge with this floor was to install the logo first, and then butt the double broadcast into the logo.

2. Apply primer coat of epoxy

The purpose of the primer is to catch the broadcast.  When the flake is broadcasted into the primer, it will hold onto a majority of the broadcast.

Step 3. Broadcast

The broadcast will need to adequately cover the entire floor.  The broadcast will stick to the epoxy.  But there will be leftover broadcast that does not stick to the epoxy.   This will need to be swept off the floor before the 2nd coat of epoxy gets installed over the 1st broadcast.

Step 4. The 2nd coat of epoxy.  And broadcast into the 2nd coat.

After sweeping the 1st broadcast that didn’t stick to the epoxy, you’ll need to apply a 2nd coat of epoxy onto the broadcast.  Apply it the same way, using a squeegee and roller.  But be prepared to use extra material.  The first broadcast will absorb a lot of epoxy, meaning you’ll need more epoxy to adequately cover the first broadcast.

After applying the 2nd coat of epoxy, you’ll want to distribute the 2nd broadcast.  Using the same motion, broadcast the chip flakes over the floor.  Be sure to cover every spot , so there are no gaps or inconsistencies in the floor with the broadcast.

Step 5. Sweep the Broadcast, and apply the grout coats.

Again, the remaining broadcast that did not stick to the epoxy will need to be swept before applying the grout coats.  After the broadcast has been swept 2-3 grout coats can be applied.  The purpose of the group coats is to seal the broadcast into the floor.  Grout coats are typically performed with epoxies, but sometimes they can be completed with polyaspartic, or even aliphatic urethanes.    Keep in mind that your first grout coat will require more liquid because of the absorbency of the broadcast.  The 2nd coat will stretch further, but you’ll still need more than if you didn’t have a broadcast system.

And with the proper execution, your broadcast floor can achieve a beautiful finish, while offering a slip resistance to maintain worker safety in the shop.