Industry guidance from FeRFA emphasises that selecting the correct surface-preparation method is essential to achieving adhesion and the expected life of a resin flooring system.

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For this reason, preparation should never be considered simply as cleaning the floor. It is the process of assessing, repairing, cleaning and mechanically preparing the substrate to create a sound and appropriate surface onto which the Aspartech system can securely bond.

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Assess the Substrate First

Before preparation begins, the existing floor should be thoroughly inspected.

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The installer should consider:

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• The type and age of the substrate.

• Surface strength and condition.

• Moisture content.

• Surface porosity.

• Existing coatings or treatments.

• Oil, grease and chemical contamination.

• Laitance and weak surface material.

• Cracks, joints, holes and damaged concrete.

• Surface regularity and changes in level.

• Previous repairs.

• The presence and condition of any damp-proof membrane.

• The intended use and loading of the finished floor.

 

This initial assessment helps determine both the preparation method and the most appropriate Aspartech system.

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Mechanical Surface Preparation

For most industrial concrete floors, mechanical preparation is the preferred method.

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Depending upon the condition of the substrate and the system being installed, this may include diamond grinding, vacuum-assisted shot blasting, planing or scarifying.

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The objective is not simply to make the concrete look clean. Preparation should remove laitance, weak material and incompatible existing coatings while producing a clean, sound and suitably textured surface.

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This principle is consistent with established resin-flooring guidance, which recommends mechanical preparation to remove cement laitance and achieve an open-textured surface. The degree of preparation required should always be appropriate to the thickness and type of Aspartech system being installed.

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Remove Contamination

Resin flooring relies upon adhesion to the substrate. Anything positioned between the resin and the concrete can potentially become the weakest part of that bond.

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The prepared surface should therefore be free from:

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• Dust

• Dirt

• Oil

• Grease

• Laitance

• Loose concrete

• Wax

• Paint

• Previous coatings

• Cleaning residues

• Surface treatments

• Other adhesion-inhibiting contaminants

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Oil and chemical contamination can penetrate significantly below the visible surface of concrete, particularly in older engineering workshops, factories and warehouses. Simply grinding the visible surface may therefore be insufficient where deep contamination is present.

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Areas of questionable contamination should be investigated and treated appropriately before proceeding.

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Remove Weak Concrete

The strength of the resin system is of little benefit if it is bonded to a weak layer of concrete.

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Laitance, friable concrete and other poorly bonded material should be removed until a sound and mechanically stable substrate is exposed. Blowholes, voids and defects may become more apparent during this process and should be properly repaired before subsequent layers are applied.

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Where substrate strength is uncertain, appropriate testing such as a pull-off adhesion test can provide useful quantitative information. For context, industry guidance commonly references minimum substrate tensile strengths around 1.5 N/mm² for many resin systems, although the requirements of the individual Aspartech product and project specification should always be followed.

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Cracks, Holes & Damaged Concrete

Mechanical preparation frequently exposes defects that were previously hidden.

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Cracks should be assessed to establish whether they are static or subject to movement. Static defects may be suitable for resin repair, while active or structural movement requires appropriate consideration rather than simply being covered with a rigid flooring system.

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Holes, blowholes, spalled concrete and other defects should be repaired using a compatible repair material.

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Existing movement and construction joints should also be identified and treated as part of the flooring design rather than indiscriminately filled and coated.

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When to Use Aspartech BASE

Not every prepared concrete floor provides the ideal surface for the final resin finish.

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Where the substrate is porous, uneven, irregular or otherwise unsuitable for the direct application of the selected finishing system, Aspartech BASE can be installed to create a more consistent base.

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Aspartech BASE is specifically designed to be used beneath:

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  Aspartech FLOORCOAT
  Aspartech CLEANZONE
  Aspartech CLEARCOAT

 

Using Aspartech BASE can be particularly beneficial where the existing substrate has significant porosity, variable texture or insufficient surface regularity, or where a more uniform base is desirable before application of the final Aspartech system.

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A correctly installed base coat can help provide a more consistent surface, reduce the influence of variations within the underlying concrete and improve the overall quality and appearance of the subsequent flooring system.

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It is important, however, to distinguish levelling from structural repair. Significant cracks, deep holes, unstable concrete or structural defects should be properly repaired rather than simply concealed beneath a base coat.

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Porous Concrete

Porosity can have a significant influence on resin flooring.

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Highly porous concrete can absorb resin unevenly, increasing consumption and potentially contributing to variations in film build or the formation of surface defects.

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FeRFA guidance specifically identifies substrate porosity as one of the factors affecting resin coverage rates.

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Where porosity is significant, the appropriate Aspartech primer and/or Aspartech BASE can be incorporated into the system to provide a more consistent substrate before FLOORCOAT, CLEANZONE or CLEARCOAT is installed.

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Surface Regularity

Thin resin coatings generally follow the profile of the substrate beneath them. They should not be expected to disguise significant undulations or poor-quality concrete.

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High points can often be removed mechanically by grinding, while low areas and irregular surfaces may require levelling.

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Where greater surface regularity is required, Aspartech BASE provides an effective means of producing a smoother and more consistent base for the subsequent Aspartech finish.

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This is particularly valuable where the final appearance is important or where variations in the existing floor could otherwise influence the thickness and uniformity of the finished coating.

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Remove Every Trace of Dust

Mechanical preparation produces substantial quantities of fine dust, and removing it is essential.

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The prepared surface should be thoroughly cleaned using suitable industrial vacuum extraction before resin application. Sweeping alone may redistribute fine dust rather than remove it.

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FeRFA specifically recommends thoroughly vacuuming the prepared surface and preventing traffic from passing over the area between preparation and application.

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Once prepared and cleaned, the floor should therefore be treated as a controlled surface. Avoid unnecessary foot traffic, vehicles or other activities that could reintroduce contamination.

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Check Moisture & Environmental Conditions

Surface preparation also includes confirming that conditions are suitable for application.

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Before applying an Aspartech product, installers should check the relevant parameters specified within its Technical Data Sheet, including where applicable:

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• Substrate moisture

• Ambient temperature

• Substrate temperature

• Relative humidity

• Dew point

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These measurements provide information that visual inspection cannot.

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A concrete floor may appear perfectly dry while containing elevated moisture, and condensation can form on a surface without being immediately obvious. Environmental measurements should ideally be recorded as part of the installation documentation, providing a permanent record of the conditions present when the floor was installed.

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Consider a Test Area

Older or unusual substrates are not always predictable.

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Where there is uncertainty regarding contamination, adhesion, an existing coating or the compatibility of a particular substrate, installing a small trial or test area can provide valuable information before committing to the complete installation.

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Bond testing may also be appropriate for particularly demanding projects.

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Preparation Should Match the System

There is no single preparation method suitable for every resin floor.

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A lightly trafficked commercial coating, hygienic flooring installation and heavily trafficked industrial system may require very different preparation.

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The correct method should therefore be selected according to the existing substrate, its condition, the intended Aspartech system and the demands that will subsequently be placed upon the floor.

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Excessive preparation can unnecessarily damage a substrate, while insufficient preparation can leave behind the very material that ultimately causes the system to fail.

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Preparation Is an Investment, Not an Extra

Surface preparation can represent a significant part of a professional resin flooring installation, but reducing preparation to save time or cost can be a false economy.

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Poor preparation can contribute to loss of adhesion, delamination, pinholing, uneven appearance and premature failure. FeRFA similarly identifies preparation as a fundamental stage capable of determining the success or failure of subsequent flooring applications.

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A properly assessed and prepared substrate gives Aspartech FLOORCOAT, CLEANZONE, CLEARCOAT and the wider Aspartech range the foundation required to deliver their intended performance.

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Inspect it. Test it. Prepare it. Record it. Then coat it.

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The quality of a resin floor ultimately depends upon something that can no longer be seen once the installation is complete – the quality of the surface underneath it.