At Ironpour Resin Flooring, we keep the process simple for you. Here is how your epoxy flake flooring system goes in.
We Bring the Tools, Survey the Site and Prepare the Concrete
At Ironpour Resin Flooring, we turn up with our own tools, including diamond grinders with a vacuum fitted, squeegees, rollers, a mixing station and a floor scraper. We also supply all the material for your epoxy flake flooring system, from the primer to the flakes to the clear sealer. Our crew wear gloves and keep the site tidy.
Every job starts with a visit to check the concrete and test moisture. Surface preparation is what makes a durable epoxy coating, so we never rush it. Concrete must be clean, dry, and mechanically profiled, and we prefer diamond grinding to acid etching for this.
We never lay epoxy on a dirty concrete surface. Once the concrete is ground, we use vacuums and the right tools to keep dust under control, fix cracks and holes, scrape away old residue, and scrape high spots level. Too much moisture can lead to blistering or peeling of the coating, and on new or porous concrete, a moisture seal primer can improve adhesion.
We Handle the Mixing, Lay the Base Coat, and Broadcast the Flakes
Careful mixing matters, because poor mixing ruins a batch. We mix the epoxy and hardener in a clean mixing container, following the manufacturer's instructions. Mixing ratios must be right every time to achieve full strength.
Epoxy has a short pot life and starts to harden fast once mixing ends, so we work as a team. We apply epoxy with a notched squeegee and a roller, and we use a flat blade squeegee to level it. Pot life is short, so we move fast.
Our crew walks the floor wearing spiked shoes, so we leave no footprints in the wet epoxy. Spiked shoes protect the wet base coat, and they stay on until the last flake is down. Without spiked shoes, every footstep would leave a mark.
We apply flakes while the base coat is still wet, because that is how they lock in. The flake broadcast carries on until the floor has complete coverage, then we let the base coat harden. Good mixing and a steady flake broadcast help us achieve an even look, so we apply epoxy in even coats and apply flakes by hand.
We Clean Up, Seal the Floor and Manage the Curing
Once the base coat has hardened, we scrape off the loose flakes with a floor scraper and a putty knife, then vacuum the floor. Next comes a protective topcoat that locks in the flakes and adds chemical resistance and wear protection. That topcoat also helps create a smooth finish that is easy to wipe.
A topcoat applied correctly seals every flake, but a rushed topcoat leaves shiny spots. Our clear topcoat is durable and thick enough to take daily knocks. Poor curing leaves soft patches in the floor coating, so we plan around the curing window.
Curing is where a good epoxy flake floor becomes a great one. Cure times vary with temperature, humidity, and the product, and the full cure can run longer depending on the weather. Good curing needs steady temperature and low dampness, so we tell you when it is safe to walk on your epoxy flake floor once curing ends.
2025 was the UK's warmest year on record in the Met Office series that dates back to 1884, and rainfall hit 1,041.2 mm, around 90% of the 1991 to 2020 average. In southern and central England, March to August rainfall was widely below 50% of average, so we check temperature and damp before every epoxy flake floor goes down, because curing depends on both.