Concrete must be mechanically ground before installing epoxy floor coatings because epoxy relies on a strong mechanical bond with the concrete surface. Simply cleaning the floor is not enough.

Every concrete slab undergoes a non-destructive moisture assessment before a flooring system is selected. For newly poured concrete or slabs exhibiting elevated moisture levels, we include comprehensive moisture testing and appropriate mitigation measures as part of the project scope to ensure long-term coating performance.

Rockhard Fusion Primer penetrates and seals the concrete surface, eliminating pore-related issues such as outgassing that can lead to bubbles and pinholes in the coating system. It also forms a molecular bond with the subsequent base coat, creating exceptional adhesion. Independent testing has measured bond strength at 925 PSI—strong enough that the concrete itself fails before the bond releases. We apply primer on every installation, without exception.

A 100% solids epoxy base coat is installed at a thickness of 15–20 mils to create a durable foundation for the flooring system. For flake floors, decorative chips are broadcast to rejection, meaning flakes are continuously applied until the entire surface is covered and no wet epoxy remains visible. Metallic systems are poured at a heavier build of 20–40 mils, with the metallic pigments carefully manipulated by hand to create unique patterns and visual depth. For quartz applications, natural silica aggregate is broadcast into the wet epoxy base coat to maximize slip resistance and surface grip.

The final stage consists of two coats of durable, hard-wearing polyaspartic topcoat. These layers secure and protect the colour beneath, provide resistance against abrasion and everyday wear, and create the floor’s finished appearance.