How to Lay Epoxy Resin Flooring Step-by-Step (Full Contractor Guide)

Professional guide to laying epoxy resin flooring from surface prep to final cure. Includes tools, techniques, and pro tips for commercial installations.

Step-by-Step Installation Process

Laying epoxy resin flooring requires careful preparation and precise application to ensure a long-lasting finish. The process involves five key stages: surface preparation, priming, mixing, application, and curing. Each stage is critical to the final result, whether you're working on industrial car parks or commercial warehouses.

1. Surface Preparation

Start by grinding the concrete surface to remove any existing coatings, laitance, or contaminants. Use a diamond grinder for best results, creating a profile that allows the epoxy to bond properly. Check for moisture using a plastic sheet test – leave it taped down for 24 hours and check for condensation underneath.

Remove all dust with an industrial vacuum, then clean with a degreaser. The surface must be completely dry before moving forward. Any moisture will cause the epoxy to bubble and fail.

2. Priming the Surface

Apply a penetrating primer to seal the surface and improve adhesion. For porous concrete, use a two-part epoxy primer. Mix thoroughly according to manufacturer instructions and apply with a roller, working in sections. Allow 4-6 hours for the primer to cure before applying the main coat.

3. Mixing the Epoxy

Epoxy resin systems come in two parts: resin and hardener. Pour the hardener into the resin container (not the other way around) and mix with a paddle mixer for 3-4 minutes. Scrape the sides and bottom thoroughly – unmixed material will create soft spots. The mixture will have a working time of 20-40 minutes depending on temperature.

4. Application

Pour the mixed epoxy onto the floor and spread with a notched trowel or squeegee to the desired thickness (typically 2-3mm for industrial applications). Work quickly and systematically to maintain a wet edge. For areas like car parks where slip resistance is critical, broadcast anti-slip aggregates into the wet resin.

For heavy-duty environments such as warehouses, you may need to apply a second coat once the first has cured to a tacky finish (usually 12-24 hours). This builds thickness and improves durability.

5. Curing and Final Steps

Allow 48-72 hours for full cure before light foot traffic, and 7 days before heavy vehicle use. Temperature affects curing time – warmer conditions speed it up, colder weather slows it down. Maintain good ventilation throughout the curing process.

Essential Tools and Materials

Installation Time by Application Type

Pro Tips from Experienced Installers

Always dehumidify before coating – moisture is epoxy's worst enemy. Even in apparently dry conditions, concrete can hold moisture that will ruin the application.

Don't overmix the epoxy. Excessive mixing generates heat and shortens working time. Mix thoroughly but efficiently.

Work in temperatures between 10°C and 25°C for best results. Below 10°C, the cure will be too slow; above 25°C, you'll have less working time.

For more detailed guidance on getting the substrate right, check our epoxy floor preparation guide which covers moisture testing and surface profiling in depth.

Common Mistakes to Avoid

When to Call the Professionals

While small domestic projects can be tackled by experienced DIYers, commercial and industrial installations require professional expertise. Large areas, complex drainage requirements, and compliance with health and safety standards make professional installation the sensible choice.

If you're considering the DIY route, our article on DIY vs professional epoxy flooring breaks down the costs, risks, and requirements to help you make an informed decision.