Installing a Hybrid Cementitious Urethane and Epoxy Floor System

Tuesday, November 10, 2020

A recent Lakeside Painting project required the installation of a hybrid cementitious urethane and epoxy floor system. This project was one of the most complex the company has undertaken, but we and our customer are extremely pleased with the results.

Project Background

The factory and its floor is 100-plus years old. In World War II, the facility was used to manufacture tanks. Over the last century, metal studs, pipes, grime, and various floor patches were buried layer by layer in the floor. The Cudahy, Wisconsin factory's current occupant is a company that makes productions and solutions for industrial refrigeration as well as oil and gas compression.

Lakeside Painting's goal was to take a very rough, uneven, and damaged floor and resurface it into a smooth, level, durable, and easily cleanable floor with a nice appearance. Most importantly, we had to do so at an economical price for our customer.

Floor Repair

To open up the floor and see what was beneath the grime and patches, we shot-blasted the entire surface. Then we ground or jack-hammered out the metal studs and bad patching, then cleaned these areas out. We ground the enitre floor with diamond grinders twice to give the floor a profile for the floor coating systems to adhere to.

For the new floor patching, we used fast-sitting polyurea products and traditional epoxy slurry. Once complete, we did a final grind to smooth the floor.

Installing the Cementitious Urethane and Epoxy Floor System

The flooring process started with the application of one base coat of cementitious urethane primer. Before curing, we applied broadcast sand for texture. After curing, we swept and vacuumed the floor to remove excess media. We then smoothed and reduced texture by scraping and sanding where necessary.

Next, we applied one grout coat of 100% solid epoxy floor coating. Then we applied one top coat of a pigmented urethane to give it an orange hue. Together, the broadcast sand and color gave the floor the desired "orange peel" texture. After finishing the floor coating, we applied urethane safety stripes where necessary.

Final Thoughts

Lakeside Painting has seen a lot of factory floors over the years, but none with so many artifacts from a 100-year old facility. From the preparation through the coating, this was a challenging but highly rewarding project.

If your factory or warehouse is in need of a similar floor coating system, call Lakeside Painting at 262-642-9445 or email us at info@lakesidepainting.com.


Installing a Hybrid Cementitious Urethane and Epoxy Floor System
Installing a Hybrid Cementitious Urethane and Epoxy Floor System
Installing a Hybrid Cementitious Urethane and Epoxy Floor System
Installing a Hybrid Cementitious Urethane and Epoxy Floor System
Installing a Hybrid Cementitious Urethane and Epoxy Floor System
Installing a Hybrid Cementitious Urethane and Epoxy Floor System
Installing a Hybrid Cementitious Urethane and Epoxy Floor System
Installing a Hybrid Cementitious Urethane and Epoxy Floor System
Installing a Hybrid Cementitious Urethane and Epoxy Floor System
Installing a Hybrid Cementitious Urethane and Epoxy Floor System
Installing a Hybrid Cementitious Urethane and Epoxy Floor System
Installing a Hybrid Cementitious Urethane and Epoxy Floor System
Installing a Hybrid Cementitious Urethane and Epoxy Floor System
Installing a Hybrid Cementitious Urethane and Epoxy Floor System
Installing a Hybrid Cementitious Urethane and Epoxy Floor System
Installing a Hybrid Cementitious Urethane and Epoxy Floor System

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