This is some general information about installing a full broadcast flake floor. Actual installation methods will vary based on the materials used.
How many flakes do I need?
Simply put, we believe that that it is better for an inexperienced DIY customer to order more flake than he or she needs and have some left, than it is to run short. For a DIY customer we suggest taking your square footage divided by 5. So for a 500 Square foot floor you would need 100 pounds of flake. For an experienced professional, the actual amount needed is square footage divided by 6. So for that same 500 Sq. Ft. garage you would actually use 83-84 pounds. If you are wondering if you qualified as experienced, we would propose that if you are reading a post on how to apply the system, you should go with the DIY numbers.
How To Install A Full Broadcast Flake Floor
First prepare your floor in accordance with the coatings manufacturers instructions and install any recommended primer. Floors should be free of oil, dust, and other contaminants. For epoxy floors and most coatings, the floor should be adequately profiled using an acceptable grinding or shot blasting method. If applicable install the suggested primer. With Rust Bullet you would install the first coat of gray. If you are doing more than two coats, you would start the next step in your final gray coat. For epoxy we assume you are only doing one coat.
This next step is best accomplished with two people. Begin installing your coat in accordance with the instructions provided from the manufacturer. A second person should be walking behind you broadcasting flake ‘until rejection’. Continue until the whole floor is finished. Allow the appropriate amount of cure time before proceeding to the next step.
Use a quality wet / dry vacuum with the wide floor attachment. It is important to not that some attachments will leave black marks on the floor. To avoid this cover the edges of the attachment with duct tape. Applying moderate pressure use the vacuum to knock down and or remove any loose flake. When this process is complete your flakes should have a relatively even distribution and your likely feeling a little ill at the cost of the flake that did not stick. That’s normal. In order to get complete coverage you have to over-apply. A more advanced version of this method is to use a scraper and vacuum. It is more effective but also higher risk as you can remove flake that should not be removed.
The next step is the top coat. It is important to note that top coat can be accomplished in multiple ways. With epoxy it will involve at least two coats of urethane or one coat of 100% solids epoxy followed by one coat of urethane. With Rust Bullet it will involve at least two coats of clear. DO NOT go by appearance on this first coat. If you try to cover the flake, especially with urethane, you will likely put the material on to thick and risk solvent entrapment. Apply the top coats at the suggested coverage rate, regardless of appearance. Subsequent coats will cover much better.
Apply subsequent coats, use antiskid as required. Allow your floor to cure completely and enjoy!